Hodakaguy's 4x4 Sprinter Build

Hodakaguy

Adventurer
Very interesting part this.

How strong is that 3D printed adapter ?

3D is not yet in my workshop - but I see many uses for it..

Many thanks !
The adapters are pretty strong, mike built them with 80% fill. They are an awesome tool for sure!

Hodakaguy
 

Farfrumwork

Active member
Yep there are electrical contacts on the door that transfer to the speaker and door switch.

Hodakaguy

I installed a speaker in the slider on my build as well, but I had to run speaker wire down the wire track that follows under the slider step and into the door (a bit of work). I guess the passenger van has contacts, and the cargo (what I started with) does not (?). The Passenger model probably had a speaker in the door to start with eh?
 

Hodakaguy

Adventurer
I installed a speaker in the slider on my build as well, but I had to run speaker wire down the wire track that follows under the slider step and into the door (a bit of work). I guess the passenger van has contacts, and the cargo (what I started with) does not (?). The Passenger model probably had a speaker in the door to start with eh?
Yeah the passenger model already had a speaker and wiring in that location, also uses door pins for the transfer. Converting a passenger model has been great, a lot of great bits I'm re-using.

Hodakaguy
 

Hodakaguy

Adventurer
Time to get started on the bed frame.

The whole family decided to take a day trip with me to get out of the house and pick up some telescoping aluminum tubing for the bed frame fabrication. I picked up enough for myself and Mike as he is going to fabricate a frame for his van as well.

Supplies loaded up in the van....Sweet!




Starting to lay out the bed frame, I'm using a sheet of wood as a Jig. Since the walls of the van are curved the bed frame will need to extend and contract to allow mounting in different positions depending on the height of the items your carrying below the bed. I like the way the Adventure Wagon MOAB bed uses a gas strut to lock the bed into the side rails so I decided to add a strut to mine as well. The strut should also prevent any rattles while driving by keeping the entire assembly under tension.

I decided to make my bed frame in two panels, I'll be able to use one panel sideways as a single bed when traveling with the dirt bike or install both panels when the wife and I are both going.






Fabricating the mounts for the 20" x 20lb gas strut.






Miter saw with an aluminum blade is the only way to cut tubing...soooo quick and nice.




Coming together.




I'm installing a push button that will automatically lock the frame in the fully retracted position when the frame is collapsed. When removed the frames will store along the wall in a yet to be built storage rack, the button lock will keep the bed collapsed while in the rack. The button will be located on the inside of the tubing under the wood top, hidden and easy to access when you need to release the telescopic function to mount the bed.




Selecting the correct size drill bit with the help of some calipers.




Drilling the hole for the button through both the inner and outer tubing.




Recessing the outer hole so that your finger can depress the button easily.




Ready to install




The button installs by sliding the spring down the inner tubing until the button pops into the hole, a long piece of dowel works great as a push stick.








And button installation complete.




The button will be located here, hidden on the under side of the bed frame.




Getting closer...




Continued Below...
 

Hodakaguy

Adventurer
Continued from above...

Next up is to attach the 1.25" tubing to the inner 1" tubing on the telescoping end of the frame. Here I drilled holes in the outer tubing to weld the inner tubing to the outer tubing using rosette welds, this will allow me to eliminate the welds on the ends of the tubing and let the tubing have a nice flush mate up.






I'm doing the welding today, here I'm setting up the machine and welding some scrap as a test piece. Garage is a mess but I can't be bothered to clean right now :)






Filling in the rosette welds.












Welding on the inner strut mount. Always fun welding on the floor and having to use your knee on the pedal :)






I'll be using 1"x1" lock pins on the end of the frame to engage the yet to be fabricated side rail mounts. Here I'm using more rosette welds to keep the ends of the pins clean and free from welds that would interfere with a snug fit.






Getting there...




More to come....

Hodakaguy
 

Hodakaguy

Adventurer
Little more work on the bed frame today.

Unit is tacked and out of the jig for welding.








Adding the second strut mount.












Assembled with the strut temporarily in place. The unit slides harder than I would like as the tolerances between the tubing are very tight and there is very little allowance for any warping while welding. I'll look at it tomorrow and see what can be done, either way it's sliding and functional :)








More to come....

Hodakaguy
 

ITTOG

Well-known member
I have been wondering what the strut was for. I can see now but what is the application that needs it?

The welds look great.

Sent from my Pixel 3a XL using Tapatalk
 

Highlander

The Good Shepherd
Hodakaguy

Great build Sir.
What is experience with the overall quality of the van? parts, the engine, etc.
I really like the MB van but price and maintenance cost / availability seems to be a concern to me (based on some vanlife bloggers).
 

Hodakaguy

Adventurer
I have been wondering what the strut was for. I can see now but what is the application that needs it?

The welds look great.

Sent from my Pixel 3a XL using Tapatalk
The theory on the gas strut is that it will keep tension on the mounting pins and keep the bed in place when in the van.

Hodakaguy
 

Hodakaguy

Adventurer
Hodakaguy

Great build Sir.
What is experience with the overall quality of the van? parts, the engine, etc.
I really like the MB van but price and maintenance cost / availability seems to be a concern to me (based on some vanlife bloggers).
Thanks. So far I'm really happy with the Sprinter. I'm sure in the long run the Sprinter will be more expensive to maintain then say a Transit but I much prefer the Sprinter over the Transit. We are really loving this setup!

Hodakaguy
 

Hodakaguy

Adventurer
Not a ton of pics today but I knocked out the second half of the bed frame.

Cutting all the aluminum bits to size






In the jig and ready to tack up.




Welding in the mounting pegs using rosette welds.












Going together






The two bed frames next to each other. Still have some mounting tabs to weld on and a little sanding to make the units slide properly.




Next I need to start on the side mounting rails.

Hodakaguy
 

Hodakaguy

Adventurer
Today's project...fabricate the side mounts and test fit the bed frames.

I'll be using aluminum tubing for the mounts.




Drilling the corners for the bed frame mounting holes




Transferring the marks over to the 2nd mount.




Capping the ends










Getting there




Welding on the mounting tabs.






Mounting rails installed.






Bed frames installed.
















More to come...

Hodakaguy
 
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