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Old 09-18-2018, 03:33 AM   #11
radair603
 
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

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Tap with hammer didn't do it? Also recommend practicing a bit with scrap material. Get feel for tool to avoid overdoing it. You may be rivnut expert. But just in case it's easy to over do it and then get it off center. The threads will bind and then you can get a spinner
No, I was hoping I could make them work but they’re much too tight. I am not a rivnut expert but have done a few practice nuts in my roof vent cut-out which went well. I will do a few more once I have the right bit, then start with the non-critical, out of the way locations first.
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Old 09-18-2018, 03:38 AM   #12
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

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No, I was hoping I could make them work but they’re much too tight. I am not a rivnut expert but have done a few practice nuts in my roof vent cut-out which went well. I will do a few more once I have the right bit, then start with the non-critical, out of the way locations first.


On the plus side. Smaller hole is fixable. Too big is much harder.


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Old 09-18-2018, 04:17 PM   #13
TamagoVan
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

You've probably already seen this, but a forum member posted a great description of how to install shorter seat bases.
https://sprintervanusa.com/2016/07/2...he-seat-bases/
We did this in our build (both passenger and driver) and I'm so glad we did. I'm 5'6" and the seats are perfect for me now. My partner is 6'1" and he needs to raise the seat all the way now for it to be comfortable for him, but we are both happy.
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Old 09-18-2018, 06:21 PM   #14
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Default Trim clip sealing

Another lovely and invisible task is sealing the #$%&ing trim clips. I picked up a set of four trim removal tools at NAPA for about $10 and we went to town pulling off the trim. Like many tasks, by the time you're done you have it figured out. There are a couple of Torx bolts on the inside of the doors that secure those pieces and the pieces around the wheelwells demand that you install the clips in the trim then snap it back into place. Otherwise it's a bunch of prying and pulling with hands already beat up from fishing wires and insulation.

My lady is a hard worker and a tough gal and together we knocked it out in about 1.5 hours. Glad to have it done but what about the door handles and bumpers? Or maybe I don't want to know...
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File Type: jpg Trim clip cleaning.jpg (152.3 KB, 518 views)
File Type: jpg Trim clip removal.jpg (108.3 KB, 500 views)
File Type: jpg Trim clip installation.JPG (117.4 KB, 493 views)
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Old 09-18-2018, 06:26 PM   #15
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Quote:
Originally Posted by TamagoVan View Post
You've probably already seen this, but a forum member posted a great description of how to install shorter seat bases.
https://sprintervanusa.com/2016/07/2...he-seat-bases/
We did this in our build (both passenger and driver) and I'm so glad we did. I'm 5'6" and the seats are perfect for me now. My partner is 6'1" and he needs to raise the seat all the way now for it to be comfortable for him, but we are both happy.
Thanks for that link! I should probably do the same as we are both runts and the seats are too high even at the lowest setting. I had a piece of 2" rigid foam on the floor that was just about right but looks kind of ghetto.

We have so much ahead of us this will be on the back burner for a while so we can enjoy the van for a bit. Thanks again!
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Old 09-26-2018, 09:07 PM   #16
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

With insulation and wiring just about done we can start getting panels fit. This one is critical as most of my DC components will be installed on it. Rivnuts in slightly reamed-out factory holes work really well but what a workout putting them in!
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File Type: jpg IMG_3185.jpg (134.5 KB, 477 views)
File Type: jpg IMG_3186.jpg (80.1 KB, 457 views)
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Old 10-03-2018, 03:14 AM   #17
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Some rewarding progress lately. I got both lower side panels (garage area) installed after tidying up the wiring. Built a box over the wheelwell to give the batteries a place to sit. Then installed both fuse blocks and connected the DC wires. Still have battery cables, positive buss and fuses to do. Also will be securing the batteries much more solidly and boxing them in. Looks like my passenger side fuse block pic is upside down, oops.
Attached Images
File Type: jpg Wheelwell & wiring drivers side.jpg (92.6 KB, 426 views)
File Type: jpg Wheelwell box & batteries.jpg (62.4 KB, 415 views)
File Type: jpg Wheelwell box & batteries strapped.jpg (68.5 KB, 411 views)
File Type: jpg Fuse block passenger side no cover.jpg (77.9 KB, 412 views)
File Type: jpg Fuse block driver side.jpg (152.5 KB, 407 views)

Last edited by radair603; 10-03-2018 at 03:16 AM.
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Old 10-19-2018, 08:45 PM   #18
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Finally got all my wiring done and solar system running; very exciting. I still need to box the batteries and components in and put a hinged lid on it. I'm going to slightly relocate one ANL fuse so I can lower the inverter a few inches.

Also put my plywood bed stringers on the walls - the Ikea bed rails will sit on pads screwed into these stringers. I attached the 1/2" maple plywood lower wall panels into rivnuts in factory holes, then set the 3/4" bed stringers on top of the lower panels and drilled for rivnuts to attach these. My lady and I are not tall so we can sleep sideways and are willing to have limited headroom so that the front wheels can stay on the bikes. If this gets too claustrophobic in the future it's just a matter of lowering the Ikea rail supports to lower the bed. The Ikea rails are 2-piece and adjustable in length.
Attached Images
File Type: jpg Electrical.jpg (85.3 KB, 348 views)
File Type: jpg Fridge cabinet frame.jpg (87.2 KB, 352 views)
File Type: jpg Electrical close up.jpg (148.8 KB, 340 views)
File Type: jpg Electrical from rear.jpg (128.0 KB, 335 views)

Last edited by radair603; 10-19-2018 at 08:48 PM. Reason: Sideways pics
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Old 10-20-2018, 04:38 AM   #19
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Quote:
Originally Posted by radair603 View Post
Finally got all my wiring done and solar system running; very exciting. I still need to box the batteries and components in and put a hinged lid on it. I'm going to slightly relocate one ANL fuse so I can lower the inverter a few inches.



Also put my plywood bed stringers on the walls - the Ikea bed rails will sit on pads screwed into these stringers. I attached the 1/2" maple plywood lower wall panels into rivnuts in factory holes, then set the 3/4" bed stringers on top of the lower panels and drilled for rivnuts to attach these. My lady and I are not tall so we can sleep sideways and are willing to have limited headroom so that the front wheels can stay on the bikes. If this gets too claustrophobic in the future it's just a matter of lowering the Ikea rail supports to lower the bed. The Ikea rails are 2-piece and adjustable in length.


Nice. Clean and well labeled electrical.


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Old 10-20-2018, 01:58 PM   #20
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Default Re: 2016 144" 4x4 high bed MTB-carrier build

Looks good. One suggestion. Do not rely on that ratchet strap to hold the batteries in an accident. The same goes for those screwed down right angle brackets. That battery will shear those right off, and snap that strap.

I don't know how your cabinets are secured, but sheetmetal screws into the floor and walls are not sufficient by themselves if you have anything besides clothing and lightweight items in the cabinets.
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