Hodakaguy's 4x4 Sprinter Build

Hodakaguy

Adventurer
Headliner Installation........and lights baby!

Started out this morning by cutting some pieces of select pine on the table saw to install under the fans. I should have installed these when I originally installed the ceiling fan units. The boards will serve two functions, first they will give me something anchor the ceiling panels into and 2nd they give the fan screws more of a secure bite.

Also have to have the morning coffee :)

20200418_082112-X2.jpg



Next up removing the fan units from the bases.

20200418_083234-X2.jpg


20200418_083454-X2.jpg


20200418_083746-X2.jpg



I removed the screws on the front and back ends of the fan base, next up get the wood into position. A quick clamp came in handy here.

20200418_085314-X2.jpg


20200418_085504-X2.jpg



I put some Sikaflex 221 in each screw hole and on each screw itself.

20200418_085744-X2.jpg


20200418_093240-X2.jpg


20200418_093701-X2.jpg



When I originally installed the fans I used Sikaflex 252 to seal the fans to the van roof and it's very solid. As long as the fans are off I decided to add an extra layer of leak protection by adding a coat of Dicor lap sealant.

20200418_103622-X2.jpg



Got a sweet picture of my Mandels (Socks and Sandles) :)

20200418_103912-X2.jpg


20200418_110441-X2.jpg


20200418_123718-X2.jpg


20200418_123730-X2.jpg


20200418_111016-X2.jpg



Insulation re-installed around the fan.

20200418_124640-X2.jpg


Thinsulate SM600L

20200418_125226-X2.jpg



Continued Below...

Hodakaguy
 

Hodakaguy

Adventurer
Continued from above.....

Two more layers of pine to bring the boards down to the correct height for the ceiling panels, Had to take about 1 blades width off the last board on each section to get the correct height.

20200418_131125-X2.jpg


20200418_134025-X2.jpg



Ready for the center ceiling panels.

20200418_142029-X2.jpg


20200418_145511-X2.jpg



Here I'm using a piece of heated metal to melt holes in the ceiling panel where I'll install the screws to anchor the panels in place. By melting a hole before you drill you keep the fabric from fraying.

20200418_153901-X2.jpg


20200418_154916-X2.jpg



And screws installed.

20200418_154552-X2.jpg


20200418_160257-4K.jpg



Testing the lights.....Everything worked, sweet! Lights operate off the door switch with the ceiling switch in position 1 and manually off the aux battery in position 2.

20200418_155234-4K.jpg


20200418_155317-4K.jpg


20200418_155330-4K.jpg


20200418_155337-4K.jpg



Video showing the function of the LED touch lights.

<iframe width="560" height="315" src="" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>


Still need to install the trim rings and touch up a few small items then I can move on to other areas.

More to come....

Hodakaguy
 
Last edited:

Arjan

Fossil Overlander
Very nice - that hot metal trick I need to remember....

Did you treat those wooden pieces at all before fitting them ?
 

Hodakaguy

Adventurer
Playing with the camera today.....

Coffee while on the road! Here's a quick video demonstrating the Presto Myjo coffee press. We've used this press for quite a while now and love it, it's quick to use and there is almost zero clean up! The unit is small, light weight and very inexpensive. Works awesome in conjunction with the Jetboil....hot fresh coffee in 2 minutes!



Link to the MyJo on Amazon: CLICK HERE

Link to the Peak Refuel Chicken Alfredo on Amazon: CLICK HERE

Link to the Coffee we use (French Roast) on Amazon: CLICK HERE, Variety Pack here: CLICK HERE

Link to the Jetboil Flash Stove on Amazon: CLICK HERE






Hodakaguy
 

Hodakaguy

Adventurer
Time to get the roof rack finished up so I can move back to doing inside work....

Next on the roof rack...close in these side gaps so you don't see the white bottom of the solar panel. I'll also build some filler pieces that cover the gaps on each side of the solar panel for aesthetics reasons.

Here's the gap that I'll be fabricating a cover for on each side.

20200426_143000-X2.jpg




Dialing in the pattern with FAD.....Foam Aided Design :). I used the foam board to get a good fit up before transferring the pattern to Aluminum.

20200424_163045-X2.jpg



Pattern transferred to a sheet of 1/8" aluminum. I was playing with design ideas here and had drawn in a few circles, I decided not to incorporate the holes as I have another idea that I'll add in down the road.

20200424_165334-X2.jpg



Steady hand and a Jig Saw.....cut baby cut.

20200424_165906-X2.jpg


20200424_170617-X2.jpg



Making the 2nd side.

20200426_113226-X2.jpg



Making some spacers with some 1/2" x 2" aluminum 6061-T6 stock.

20200501_120056-X2.jpg



Chop saw with aluminum blade made quick work of cutting the aluminum stock....nice and clean.

20200501_120644-X2.jpg


20200501_120726-X2.jpg



Head of a bolt makes a good tool to mark the corners before grinding.

20200501_121921-X2.jpg


20200501_144348-X2.jpg



Getting ready to drill the mounting holes.

20200501_123241-X2.jpg


20200501_123307-X2.jpg



Now to make up the solar panel end gap covers. Starting with some nice aluminum bits :)

20200501_095941-X2.jpg



You can see the gaps on each end of the panel in this shot that I'll be covering.

20200501_100622-X2.jpg



Drilling holes and using pop rivets to attach the aluminum angle to the aluminum sheet. The angle will keep the aluminum sheet from panting in the wind, making it nice and solid.

20200501_103406-X2.jpg


20200501_103709-X2.jpg



Continued Below....

Hodakaguy
 

Hodakaguy

Adventurer
Continued from above....


Starting to assemble....

20200502_065659-X2.jpg



Tucking the LP9 wiring harness up under the solar panel.

20200502_081630-4K.jpg



Starting to assemble the side and top pieces.

20200502_083444-4K.jpg


20200502_084035-4K.jpg



Wiring all tucked up and in place.

20200502_085107-4K.jpg



Tidying up the wiring on the back side of the drivers side panel

20200502_095450-4K.jpg



Solar side gap pieces installed

20200502_103233-X2.jpg



I think the front looks better with the side panels installed....Done!

P5020022-X2.jpg


P5020020-X2.jpg



Took the van for a drive to make sure adding the new panels didn't cause any new wind noise....nope, perfect!

P5020017-X2.jpg




Next up I'm installing a Pelican case to carry our light weight camping chairs, ground cloth etc. The case will be going right behind the solar panel as this area won't be utilized for much and its a perfect place to mount the case out of the way. I'll always have our chairs ect with us everywhere we go.

20200502_144128-X2.jpg




I'm using the Pelican Storm Case IM3410. These cases are super tough, water tight and lockable. They also hold up well when left outside, I had a similar case on our Syncro and it was very handy!

20200502_162217-X2.jpg


20200502_162021-X2.jpg


20200502_162036-X2.jpg



I used stainless steel sidewalk bolts to attach the case to the rack. I drilled holes through the case and used Sikaflex 221 to seal the bolts to the case to ensure the case stays 100% waterproof.

20200502_162053-X2.jpg



Quite a bit of storage inside for light weight items.

20200502_162114-X2.jpg



Double 1" fender washers on the under side, nice and solid.

20200502_161125-X2.jpg



The latches are easy to use and the case is lockable. Handy setup!

20200502_162127-X2.jpg



One last chore for the day...Brakes. For the last year I occasionally get a squeal from the brakes when stopping and it's driving me crazy. I pulled the front pads on both sides, cleaned them, applied lube to the critical areas then applied some "Disk Brake Quiet" on the back side of the pads......took a test drive and it's nice and quiet now :)

20200502_112733-X2.jpg


More to come...

Hodakaguy
 

Hodakaguy

Adventurer
great work as usual. Will the box not cast shade on the solar panel though massively reducing its efficiency?

Depending on how you park that's possible. If the sun is low on the horizon and behind the van you'll definitely get some shadowing.
 

Forum statistics

Threads
185,538
Messages
2,875,655
Members
224,922
Latest member
Randy Towles
Top