Building an Adventure Van

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

  1. a1fa

    a1fa Throttle Jockey™

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    looks good boss
  2. Hayduke

    Hayduke ///SAFETY THIRD/// Super Moderator

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    That floor is gorgeous, Ed! Come down to Salida and do our house! :lol3
  3. pfb

    pfb Riding, not skiing.

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    Floor looks great, but is slippery going to be an issue? Anything not strapped down on top of it is going to sliiiide... Rubber backed carpet will help, but the entire mat will probably slide on a sharp enough corner.
  4. Geek

    Geek oot & aboot

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    Nothing loose will be put on the floors without restraint (be it a snap in piece of 80/20 or straps); the whole "slam on the brakes and get hit in the back of the head" thing again :rofl

    Driving the van these past few months I've found that anything loose in the back becomes really annoying. I've actually been using rox straps to restrain stuff like computers & such... they work great!

    Hence the huge amount of storage space we are building into the thing... and the reason all lower cabinets are being assembled with "t-slots out".

    :freaky
  5. Gummee!

    Gummee! That's MR. Toothless

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    What Duke sez. There's actually white oak with a honey finish under all the nasty-ass carpet in the house here. Very pretty. Too bad it doesn't like dog claws!

    M
  6. Geek

    Geek oot & aboot

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    Sliding doors.

    Is there a downside?

    Upside: if the lower cabinets had sliding doors the stuff inside could be accessed when the isle is loaded with things like mountainbikes or whatever (i.e. no swing space needed for door...)

    :lurk
  7. Sheep Shagger

    Sheep Shagger Show me your fleece

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    ????? Knock the chuck off and put that gauge the spindle, then put a few different drills in it and use the gauge on the shank. That outside chuck measurement is no use the chucks are so cheaply made & turned on the home machines.
  8. leeinmemphis

    leeinmemphis Long timer

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    I totally came across this by chance but I am currently doing something very similar but with a MUCH lower budget.
  9. Cowboy

    Cowboy Ceteris non Paribus

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    Yeah, just saw your project over in Duke's Vans thread. This project started there too. In fact, I suspect Duke's thread was responsible for a lot of Geek's motivation to buy the sprinter in the first place. :lol3

    Like any Geek project, this one quickly grew to the point that it needed its own thread, for fear of completely taking over the vans thread! :freaky
  10. slackmeyer

    slackmeyer Don't mean sheeit. .

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    Dang. I think you already bought something.

    Anyway, these are the shit: long lasting and very quiet. Great price for these things, too.
  11. Geek

    Geek oot & aboot

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    I can't believe I've put 10,000 miles on the thing already :cry

    [​IMG]

    I stopped by the dealership and had the 10K service done.
    They have a few Sprinters in stock if anyone's looking :lol3

    [​IMG]


    They also had this $220,000 piece of gull-wing-goodness there for me to drool over while I was waiting :drif

    [​IMG]

    [​IMG]
  12. Geek

    Geek oot & aboot

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    We were going to go snowboarding today and work on the van tomorrow but it is windy today and not tomorrow so we switched days.

    I started the day by building the rail for the right side mounting to the van...

    First cut the 8 foot rail down to legth and then mark the location of the 6 holes:
    [​IMG]

    Using the drill jig drill the 6 holes:
    [​IMG]
    ...they end up coming out perfect thanks to the jig.
    [​IMG]

    ...and voila. The other rail is mounted to the van (again with a little bit of knuckle busting to get the nuts on the backsides.
    [​IMG]

    Cheryl spent the day cutting and gluing luxury liner pro into the slots... she's doing a great job (compare this to the photo above.. which has the black damplifier vibration damping only.. and then below the mass loaded vinyl and closed cell foam glued on):
    right rear
    [​IMG]
    left middle
    [​IMG]

    I decided to change something in my cabinet design... the rear panels have to be assembled the way that they are because of the door hinge access... but the front panels do not have to be this way:

    [​IMG]

    ...by "this way" I'm referring to the fact that the closest corner has a full height vertical, but the wall side has a vertical that is inset in the two horizontals.
    I don't have an option in the back but in the front I can make things look better..

    In the back.. the vertical is inset to allow the door hinge to fit:
    [​IMG]

    So, I pulled the panel...
    [​IMG]

    ..and am now making it with parallels. Looks tidier :thumb

    [​IMG]

    I then cut out a piece of LLP...

    [​IMG]

    ..and laminated the inside.
    [​IMG]

    I now have one very quiet cabinet wall :deal

    I built the vertical walls for the right side cabinets as well.. but I'm waiting on UPS to show up with the end connectors so I can put it all together.

    They are supposed to be here Monday along with the live hinges for the bed platform that bridges the gap. :lurk
  13. Keith

    Keith Slabbing it

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    Still looking good, keep up the pics and the good work!
  14. EJ_92606

    EJ_92606 Rider

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    I was thinking about chassis flex and how the wood will handle that...creaking and moving? And moisture/fluid spills? The wood does look incredible though! I think I would have gone with an indoor/outdoor carpet. Lighter and better sound absorption as well.
  15. Geek

    Geek oot & aboot

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    The bed platform will be carpet as will the walls below the upper cabinets and above the lower cabinets.

    I've been driving around for a week with the floor in it (though I removed it today to protect it) and the van is silent - not a sound/creek anywhere. Everything is precision fit and nothing is able to move (I'm putting a lot of effort into making sure). As of the moment.. the only "creek" I have is in the swivel of the seat I'm sitting on.. haven't figured out how to get rid of it yet :patch

    The floor is currently composed of the vans sheet metal, then damplifier, closed cel foam, mass loaded vinyl, plywood laminated with fiberglass, and then the hardwood on top of all that.
    Pretty much no sound comes through the floor anymore :D

    The luxury liner pro will be even a bigger part of this when the back of each cabinet is laminated with it (the floor already is).
  16. Geek

    Geek oot & aboot

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    It is more like 2 plates.. one over the other.

    There is an acentric post in the middle connecting them and then about a foot in diameter there are little roller wheels that the chair's weight is on as it rotates.

    I haven't looked into if it is a roller wheel or the central post that's squeaking... but I'll get to it eventually :freaky
  17. Geek

    Geek oot & aboot

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    These are the only photos I currently have.. I'll try to get "innard" photos another time

    [​IMG]

    [​IMG]
  18. Geek

    Geek oot & aboot

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    Ironically.. I think it runs on delron wheels.. I have to take a closer look. For all I know the squeak could be one of my mounting bolts not being snug :dunno
  19. Geek

    Geek oot & aboot

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    I have a torque wrench.. the german instructions didn't come with a torque spec :rofl
  20. marchyman

    marchyman Cam Killer

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