Building an Adventure Van

Discussion in 'Shiny Things' started by Geek, Aug 12, 2011.

  1. phoenix13

    phoenix13 Banned

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    was the window hole cut with a saber saw? i'm petrified of scratches from shavings.
  2. MrGoldfish

    MrGoldfish Been here awhile

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    I'm diggin' those windows. :clap

    I have to say, this is probably one of my favorite threads. Something about vans just tugs at my heart strings. Keep it coming.
  3. Geek

    Geek oot & aboot

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    Ok.... Anyone available to help me unload this :scratch

    :photog

    [​IMG]


    .mobile
  4. Geek

    Geek oot & aboot

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    I knew this project was going to be a good excuse to add to the tool collection... but if you had told me I'd end up with this many ways to cut things I would have disagreed...

    The miter saw has been essential. I use it to cut all of the 8020 and to cut wood to length
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    The table saw has been a necessary evil. I don't like it (would love to have a panel saw!) but it is the best way I have to turn a big piece of wood into a small piece of wood quickly
    [​IMG]

    I used the Fein tool originally to cut the hole in the roof (in hindsight a jigsaw would have been better). Have also used it to "scrape" with a lot less effort. This would be the least useful of all the cutters on this project and I could have done without it
    [​IMG]

    I used the Hacksaw to cut the hole in the floor for the Airtronic. It worked very well and I don't think any of the other saws could have done what it did due to the awkwardness of that cut and the thickness of the material. I've not found anything else to use it on (yet). I guess I could have rented one for the day.
    [​IMG]

    The jigsaw was used to cut the giant window holes - it worked well enough. Up until now I've also been using it to cut complex shapes but it has been a bit of a pain because the pieces I'm working on are often small so they want to move around if not clamped properly
    [​IMG]

    The dremel: a million little uses their advertising says. I think I've used 999,999 of them on this project. A must have
    [​IMG]

    ...and then today's purchase: The band saw.
    I'm already kicking myself for not buying this a year ago.. all of the frustrating little things that I"ve hacked at with the dremel and/or jigsaw to make fit.. the band saw would have been the perfect tool for. Now as I progress into the interior of the cabinets, this thing is worth its weight in.. steel :D
    [​IMG]

    Things like this:
    [​IMG]
    [​IMG]
    are a 30 second job on the bandsaw. It is soooo much easier using the right tool for the job.

    ...although I'm quickly realizing I do not know squat about building the interior of a cabinet :scratch

    Time to do some reading and learn something new. :lurk

    [​IMG]
  5. pfb

    pfb Riding, not skiing.

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    You probably are already using it for this, but conventional band saws work incredibly well for cutting aluminum as well. eg: those curved cuts you wanted to make in the 80/20 described a few pages back.

    [​IMG]
  6. AngryScot

    AngryScot .

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    Great stuff!
    If that is a cabinet, just a thought but why not have access from the outside too?
    Feel free to ignore and move on :D
  7. ian408

    ian408 Oh? Administrator

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    Nice collection of goodies! The Fein Tool comes in handy when you want to make a cut without moving the material-like cutting baseboard. They're useful but only occasionally-at least that's my opinion.
  8. Geek

    Geek oot & aboot

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    That's a great idea (I had played with the same thought) except that it's usage became defined/full when we decided the sink was going to go in that counter top. The cabinet contains the fresh water tank, grey water tank, and porta potty. Fits them exactly. :thumb

    The space at the bottom is open on the right end (from the step) - we will be rolling up the welcome matt and stuffing it in there.

    :freaky
  9. HellSickle

    HellSickle Scone Rider

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    +1 on band saws. I got one from an inmate last winter. It's actually a cutoff saw, but can be turned upright with a small table to use as a bandsaw. I don't know how I survived for so long without one.

    FYI, I used some of the proceeds from selling my KLR and picked up a large TIG welder from another inmate. Give a shout if you have any quick welding projects. :deal I think Paula needs an aluminum luggage rack for her DR.

    Next essential tool: Plasma cutter. :evil
  10. Geek

    Geek oot & aboot

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    Cool stuff Jeff!

    When my schedule turns back to bikes from Van I would like to weld a bigger foot on the 950's sidestand :deal

    :freaky
  11. Geek

    Geek oot & aboot

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    I'm really trying to make a push.. worked on the van since this morning. Was over 100 degrees in the thing in the heat of the afternoon but I got quite a bit done :thumb I just now ran out of daylight :(:

    Lots of infrastructure type stuff - for example in the photo below, between he porta poty and the water tank is one of the van's "hard points" for tie down. Hence the beefy build off of that point as I'm still trying to make sure nothing moves in a rollover accident; so I've integated each hard point with extra reenforcment whenever I junction to one:
    [​IMG]

    I still haven't decided what type of hinge system I'm going to use when I put cabinet doors on all of the lower cabinets. :scratch

    I've got the passenger side upper cabinet 3/4 done. One set of sliding doors are in (no handles yet though) and then I've sectioned off the speaker/control panel area where all the light wiring will come together:
    [​IMG]

    I'll jump back on the build when the sun comes up... :lurk
    .mobile
  12. CodyY

    CodyY ADVenture Capitalist

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    Sun's up here.


    Slacker.
    :D
  13. Geek

    Geek oot & aboot

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    I try and not use the power tools until 8am for the sake of the neighbors. I've spent the last hour cleaning the garage (it is a disaster!) :D


    .mobile
  14. TooFast

    TooFast Long timer

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    Nice job an the window installs Geek! Are you nearing mods completion?
  15. TooFast

    TooFast Long timer

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    Enjoy your self, tig welding can be an art of beauty, most versatile, manipulative welding method system available. I'm going to be trying a stich process on .032 sheet metal soon (warping) many things to master!

  16. Geek

    Geek oot & aboot

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    Some photos I snapped that had the Sprinter in them this morning :)

    [​IMG]

    [​IMG]

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    Looks like I left the roof vent open :rofl
    [​IMG]
  17. a1fa

    a1fa Throttle Jockey™

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    nice!
  18. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    Congratulations, Geek and Tweetie! :clap:freaky
  19. Trixie

    Trixie No, not that Trixie

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    It's been far too long since anyone has pointed out just how much you suck. :D


    Nice pics.
  20. Geek

    Geek oot & aboot

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    As we're driving down the road this is what I see over my shoulder.

    I'm jealous of the dog. I would rather ride back there and she can drive.

    [​IMG]


    .mobile