Introducing myself and my project

You should hook up with some Tiger 4x4 people to get the correct application of insulation and van-specific issues. One thing i did notice was your pending adding weight to the AstroVan will push the suspension a bit hard. So, over-sized gas shocks are in order. And, always buy more tire than you think you will need, capacity-wise. I would even go an E rated tire for your rig. Not bigger, just more capy. The ride will suffer, but you will be far from the GVW limit. The other thing is: get a bigger transmission oil cooler than you have now. The thing that zaps trannies is heat. I don't think a small, hard side TC would cause much more notice while stealth camping than a van all decked out for camping. The thing is to have nothing outside the rig that would give pause to the locals. Selecting a place for a night in the city is an art form developed to its full potential by Tioga George. Look up his blog.
jefe