CARGO COMPARTMENTS
I sized my rear cargo compartments based on multiple needs. One requirement was the compartments being short enough in height to allow bike pedals to overhang the compartments. This allows me to place bikes adjacent to the compartment fitting up to 5 bikes across. The compartments had to be wide enough to fully enclose the wheel wells and also accept multiple GC2 batteries mounted sideways. The result is a compartment on each side measuring approximately 12 x12” and about 72” in length.
I installed a total of four identical and interchangeable lids. Each lid included a 3” wide fixed portion along the walls which allows me to vertically store my bed panels without interfering with the hinged lid. The wall mounted L-Track secures the bed panels. The hinged openings are just big enough for a GC2 battery to fit thru. I currently have my batteries under the van but want the option of mounting lithium batteries in the compartments.
I also positioned the hinged lids vertically to provide a 1/8” gap on the underside of one edge when closed. This allows me to install lower bed panels that straddle the two side compartments without interfering with the operation of the compartment lids. Small rubber bumpers on the underside of each lid keep it level.
The compartments are fabricated from 3/4” thin wall steel tubing painted black. Each frame weighs about 15 lbs. the bottom leg is bolted through the floor using 5/16 stainless bolts. The wall side is attached using the same 5/16” bolts and Rivnuts installed in the van structure. I inserted a scrap of fabric covered panel between the compartment frame and the wall during initial construction to simulate the yet to be built wall panels.
Before installing the steel frames I covered each wheel well with a layer of Noico/Kilmat, followed by a 1/4 layer of minicell foam, and finally the factory rubber wheel well covers. The wheel wells are a huge source of noise. The factory wheel well covers fit over the added minicell foam because I had raised the floor by 1/2” thus creating the added space.
The cargo compartment walls consist of 1/4” wood floor underlayment covered with Loncoin. I glued the Loncoin to the slightly oversized panels using Roberts 2310 floor adhesive. I then cut the panels to size on a table saw. The result is a clean edge. The panels were then attached to the steel tubing using construction adhesive. I painted the one exposed wood edge with black paint to match the adjacent black steel. This edge is covered by the lid either way. I trimmed out the corner with 1/2” aluminum angle.
The top to each compartment was fabricated in a similar manner as the walls. The tops are 1/2” pre-finished maple again covered with the Loncoin and cut to size. The bottom edge is notched using a table saw so that the 3/4” aluminum channel will fit snugly over the edge including the Loncoin. The aluminum channel is secured using construction adhesive. The 3/4” channel was a unique size I found at Home Depot. The local metal supply house with a large inventory did not carry the same size.
The location of the 35mm hinge holes initially posed a problem. They overlapped the aluminum channel. Luckily a sharp properly sized hole saw made quick work of the hinge holes. A 35mm forstner bit cleaned out the remaining wood. All four lids were identically sized as were the positions of the hinges so they are interchangeable. The holes for the latches were straightforward. I used Southco black plastic latches that have proven to be reliable and quiet.
The hinges are 110 degree Blum soft close. As is typical with European style hinges these included quick releases allowing easy removal of the lids if necessary.
The fixed portion of the lids were attached to the steel frame using construction adhesive. An 1/8” spacer was also inserted between the lid and frame to provide the earlier mentioned 1/8” gap for my lower aluminum bed panels, yet to be built.
I had previously run Pex plumbing to the passenger side compartment for my outdoor shower. I also ran a 30 amp AC circuit to the driver side for a potential generator feed. My air compressor was mounted on the drivers side below the floor. I used a pair of matching black 3 x 5” recessed panels for the shower connection and the air compressor connection. Details of these panels were covered in earlier posts.
At this point in time the compartments are partially filled with “full time” camping gear including both small and large sand mats, multiple camp chairs, a tool bag, tow strap, bike pump, spare blankets, and other miscellaneous gear.
