T1N Cargo Conversion - Sprinter-Forum

Colorado_Al · 10-12-2010, 01:04 AM

Things are moving along on the 03 158" cargo conversion.
First thing I did was install an aux battery system using the BlueSea SI-Series Automatic Charging Relay #7610 and a Cabela's Advanced Angler AGM Battery. Hooked up the center console, radio, cargo lights to the aux battery and also installed 2 12v outlets in the rear. Also ran wire for a roof fan.
Then I added a 2 person Sprinter bench seat. Used rivnuts to mount the tracks.
Before I was going to do any more work on the van, I needed better tunes! The stock radio was crap! I ordered a Sony head unit from Crutchfield and it arrived 3 days later. I installed it and put new 4" front speakers in (The Wallyworld VR3 $24 special!) Also ran speaker wire for rear speakers.
Then the insulation began! There is a place about 1/2 mile from our place in St. Louis called Diversified foam products. They normally sell to other large businesses, but they sell seconds or overstock to the general public. I went there looking for styrofoam and ended up buying 150 sq ft of 1/2" medium density closed cell rubber for $50! Hello sound insulation! I installed the 1/2" foam with spray adhesive and started with the ceiling working my way down. I did not have quite enough to finish the entire van, but I will buy Dynamat for the rest.
Then I put in styrofoam insulation and then reflectix.
I also liquid nailed a frame for a future roof fan, that I'll install when it arrives.
Next step is installing a ceiling, which I'm thinking of doing out of bendable plywood.

Here are some pics of the project.

Colorado_Al · 10-12-2010, 01:09 AM

More pictures
Also added a 150 Amp alternator and Roadmaster Active Auaspension.

mackconsult · 10-12-2010, 03:08 AM

Nice Al !!!!! Keep up the posts.

Afigman · 10-12-2010, 04:53 AM

My van is a 140 tin high top. Instead of bendable plywood I had a piece of aluminum bent at a angle about 10 feet long bent to fit the corner. I used rivit nuts to attach it to the upper ribs. Then I used luan plywood covered with indoor outdoor carpet glued on with contact cement and used rivit nuts to attach it to the angle and ceiling ribs. Very simple and easy to remove. I removed the side panel for the picture. I left the black foam as it was simple to work around and it looks finished. I bent a 1-1/2x1-1/2 aluminum angle to match the back curve of the headliner and screwed it to the side of the ceiling rib so the luan would match the head liner. Looks flawless. Because the plywood only comes 4' wide I cut 2 strips 2-1/2" wide and glued them to the carpet on each side of the 4' wide panel. The end result was a panel 4'5 wide x 6'6 and 4'x 4'. Two panels make the roof. Luan ply and Home Depot indoor outdoor carpet is inexpensive. I included a pdf of the angle I used.

Colorado_Al · 10-12-2010, 05:30 AM

Quote:

Originally Posted by Afigman

My van is a 140 tin high top. Instead of bendable plywood I had a piece of aluminum bent at a angle about 10 feet long bent to fit the corner. I used rivit nuts to attach it to the upper ribs. Then I used luan plywood covered with indoor outdoor carpet glued on with contact cement and used rivit nuts to attach it to the angle and ceiling ribs. Very simple and easy to remove. I removed the side panel for the picture. I left the black foam as it was simple to work around and it looks finished. I bent a 1-1/2x1-1/2 aluminum angle to match the back curve of the headliner and screwed it to the side of the ceiling rib so the luan would match the head liner. Looks flawless. Because the plywood only comes 4' wide I cut 2 strips 2-1/2" wide and glued them to the carpet on each side of the 4' wide panel. The end result was a panel 4'5 wide x 6'6 and 4'x 4'. Two panels make the roof. Luan ply and Home Depot indoor outdoor carpet is inexpensive. I included a pdf of the angle I used.

I thought about doing a flat piece for the top and a flat piece for the sides. I did some checking, and there is a hardwood ply distributer about 5 miles from me where I can get the bending lauan ply for about $25/sheet. I'm going to give it a try and see what I can do. If it doesn't work out, I'll use the ply for some other project.

maxextz · 10-12-2010, 10:56 AM

great insulation going on there al

do you have any more pics?

Colorado_Al · 10-13-2010, 12:04 AM

Quote:

Originally Posted by maxextz

do you have any more pics?

I'd like to see more too.
I have changed course on the bending plywood, as the available stock here in St. Louis is crap.
Going to do a similar idea to Afigman.
Thanks for the help!

teamtexas · 10-13-2010, 12:14 AM

Keep up the good work Al. That looks like a quiet ride already. I'm sure it will only get better once you get the covering up there!

Dan

Afigman · 10-13-2010, 04:30 AM

I will take some pictures post tomorrow. Was the pdf autocad drawing clear?

Afigman · 10-13-2010, 11:23 PM

I posted pictures of the ceiling on a new thread called (my surf, camp and work van. )I posted it in Tin Right-ups. May be the moderator could move it to Sprinter RV's & conversions Write- ups. I don't want to hijack this thread as I need to copy Colorado Al's aux battery set up. Please post more on that Al.

10-12-2010, 03:08 AM	#3
mackconsult Join Date: Dec 2008 Location: Vancouver, WA, USA Posts: 1,349 Thanks: 285 Thanked 144 Times in 126 Posts	Re: Conversion coming along! Nice Al !!!!! Keep up the posts. __________________ 97 XR600R Honda Dual Sport Motorcycle 98 18' Avon RIB w/ 90 HP 4 stroke Yamaha 95 TDI Passat VW Wagon 05 2500 140" normal height sprinter van w/ veggie oil conversion kit 08 Laser Pro #194171 Vancouver, Washington, USA Sail Smart, Sail Hard, Then think about Sailing Fast !!!!! http://www.mackconsult.com/ Some day I will sell everything, buy a cascade 36 or a cal 40 sailboat, and turn left at the Columbia River Bar !!!!

10-12-2010, 10:56 AM	#6
maxextz Rollin Rollin Rollin..... Join Date: Apr 2008 Location: Dublin Ireland Posts: 3,436 Thanks: 932 Thanked 1,004 Times in 583 Posts	Re: Conversion coming along! great insulation going on there al do you have any more pics? __________________ Sioux-316CDI/T1N/158/2005. Light Prevails

10-13-2010, 12:14 AM	#8
teamtexas A Dad owner with a '03 Join Date: Aug 2009 Location: Gatesville, Texas Posts: 721 Thanks: 149 Thanked 220 Times in 145 Posts	Re: T1N Cargo Conversion Keep up the good work Al. That looks like a quiet ride already. I'm sure it will only get better once you get the covering up there! Dan

10-13-2010, 04:30 AM	#9
Afigman Afigman Join Date: May 2009 Location: Ventura CA Posts: 70 Thanks: 2 Thanked 24 Times in 14 Posts	Re: T1N Cargo Conversion I will take some pictures post tomorrow. Was the pdf autocad drawing clear? Last edited by Afigman; 10-13-2010 at 04:35 AM.

10-13-2010, 11:23 PM	#10
Afigman Afigman Join Date: May 2009 Location: Ventura CA Posts: 70 Thanks: 2 Thanked 24 Times in 14 Posts	Re: T1N Cargo Conversion I posted pictures of the ceiling on a new thread called (my surf, camp and work van. )I posted it in Tin Right-ups. May be the moderator could move it to Sprinter RV's & conversions Write- ups. I don't want to hijack this thread as I need to copy Colorado Al's aux battery set up. Please post more on that Al.

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