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Old 08-05-2013, 06:22 PM   #1
Evil Patrick
 
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Default Evil Sprintel

The starting point.

A lot of us have been here.



Now, I don’t have pics for a huge part of the initial steps of the build out, but I do have some video, which I will publish soon. This includes things like showing the Damplifier, building and trimming the wheel benches, building the wall panels, installing plusnuts, etc.

Stay tuned…
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2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

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Old 08-05-2013, 06:23 PM   #2
Evil Patrick
 
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Default Re: Evil Sprintel

Wheel benches

My floor plan suspends a queen bed above the wheel wells, giving ample room beneath for storage while positioning the bed to provide a garage that allows the MTBs to be stored inside, if needed, as well as providing a place for an indoor bathroom (shower, luggable loo). I built two wheel benches out of ¾ inch birch plywood. I trimmed these with 1/8th inch AL. I bolted these to the walls with 2 by 2, 1/8th inch angle AL that is secured with ¼ 20 plusnuts in the walls and ¼ 20 bolts through the benches. I actually have some video of this.

Minwax Jacobean and clear satin polyurethane on birch



Here’s a wheel bench partially loaded with stuff



BTW, the above shots show a lot of the rubber floor, which I’ll get to next…
__________________
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2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:24 PM   #3
Evil Patrick
 
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Default The rubber floor

For my flooring, I bought some recycled rubber mats from Home depot. These are Apache Mills Black 48 in. x 72 in. Commercial Recycled Rubber Outdoor Mats.

http://www.homedepot.com/p/Apache-Mi...0600/100671752

I used 3 of these and purposely installed them upside down. The back side is smooth. The top side has heavily tread.

Here are some shots of the floor in the garage.





You can also see shots in the previous post as well as throughout this write-up.

These needed to be left outside for about a month to outgas. Now, there is no noticeable rubber smell whatsoever.
__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:24 PM   #4
Evil Patrick
 
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Default More pics

Here’s a pre-ceiling pic. You can see the wheel benches with some things stowed, the rubber floor, the wall panels, the shelf base, some quick tables…



and here you can see the 1.5 inch R-max Plus in between the ceiling ribs

__________________
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2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:25 PM   #5
Evil Patrick
 
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Default The bed slats

The bed slats are 18” by 67.5” of 3/4” sanded pine plywood. Together, they make a bed platform that’s 72” long by the width of the van. Since the AL rails they attach to are actually 8’ long, I can add length to this, if desired, but that would encroach into my “garage” space, making it difficult to have the bikes inside, or the shower up at the same time that the bed was longer than 72”. But there’s a configurable option.


In the van, laid up all four beds slats on the top of the wheel benches. Meticulously spaced the slats by stacking equal numbers of fender washers, on edge, all around the bed slats. Also, evenly stacked fender washers as spacers between the slats to allow room for the fabric that would cover these slats. I think I used about 100 fender washers in total. Marked the hole locations for the bed slats. Unbolted the benches and rails. Used the drill press to drill the ¼ inch holes in the rails. Bolted the rails back to the benches. Drilled and tapped (through the AL and the ¾ birch below that). Bolted and tightened the benches to the walls.


I covered bed slats w/ fabric. This is some type of tarp fabric. It’s infused with a flexible, water-proof, polymer backing.

Using McMaster Carr parts, built 8 thumb-bolts that are used to quickly connect and disconnect the bed slats. These are made from 18-8 stainless steel, fully threaded studs, 1/4"-20 thread, 3" long, along with eye-nut adapters for threaded rod, for 1/4"-20, and a couple of ¼” nuts, lock washers, and a fender washer on each.

Here is a home-assembled bed slat anchor bolt





One bed slat laying in place



bed slat anchor bolt, partially inserted



All bed slats in place

__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:26 PM   #6
Evil Patrick
 
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Default Shower

Built a nice, 2.5 sq ft shower curtain rod hoop. I use a 10 ft piece of 1” copper pipe. I used my tube bender and got some nice, smooth radiuses. I put 2 t-nuts in the middle and left ceiling trim boards. Shower egress is from the middle of the van. Threaded in eye-bolts. Snapped in some carabineers. Daisy-chained 2 shower rings to each middle carabineer. Looped the shower rod into the bottom shower rings. Hung 2 shower curtains around the rod. Taped these together. Put washers around the bottom as weights. The whole shebang clips up in seconds and comes down just as quickly. I can fold the curtains flat around the hoop and store it on or against the wall, in the back, out of the way. The interior shower is so nice that we’re probably never going to use the pop-up privy again!


shower hoop attachment







I added a drain to the shower pan.

Here’s shower pan bottom, showing drain hose set-up



I built a shower floor so that we could simply deploy a drain hose to dump the grey water.

Here’s shower pan floor





Here’s the shower pan in place





Here’s the shower up





By quickly unhooking 2 of the carabineers, I can drop the shower mostly out of the way of the garage space



To actually shower, I’m using a Rule Charge-n-Flow pump to pull sun shower-heated water from either the sun shower bag or a large thermos.
__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:27 PM   #7
Evil Patrick
 
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Default The shelf system

Out of ½” birch plywood, I built a 3-shelf, 4 cubby system, 30 inches wide, with shelves spaced about 18” apart. The walls are bolted to the van’s wall and only stick out 12” at the bottom and about 6” at the top. The shelves, however, are 20 inches deep. They are cantilevered. They slide in and are trapped by thumb bolts that actually just slide down through holes in the shelves. It only takes seconds to install and remove the shelves. When the shelves are removed, most of the van interior space right behind the seats is once again available. There are eye bolts on both sides of each shelf cubby. Slide the clear plastic storage bins onto a shelf and use the eye bolts to bungee in. I stained and sealed the wood and added some angle AL to the front edges of the walls to make it blend w/ the look and finish of the wheel benches.

Here’s a shot of the base, without the shelves installed



Here are the shelves removed and queued for installation



sliding a shelf into its track





a pin is inserted



and pushed on in



another view of a shelf locked in place



Here’s a shot of the cantilevered shelves up



These shelves hold a boatload of plastic storage tubs.
__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:28 PM   #8
Evil Patrick
 
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Default The ceiling

For the ceiling, I picked up some solid, 3” wide, 8’ long, 1” thick birch for ceiling accents. These were stained and poly’ed to match the benches and shelves.
The ceiling is:

• the 1.5 inch R-max Plus in between the ribs
• a layer of ½ inch R-max
• coreplas
• all held in place with a wooden trim matrix that’s bolted to plusnuts

Here are some shots of the ceiling going up. Raw trim boards are holding ½ inch R-max in place







Here’s a shot of the ceiling up

__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:28 PM   #9
Evil Patrick
 
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Default Sexy curves

To finish the curve between the wall and the ceiling, I fab’ed some strips of coreplas that get trapped by the bolts that hold the ceiling boards in place and the bolts that hold the wall panels in place. To make the coreplas gently curve, I used a special coreplas cutter to cut the flutes on what would be the backside of the sheet.

Here are a bunch of pics of the wall / ceiling junction













__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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Old 08-05-2013, 06:29 PM   #10
Evil Patrick
 
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Default Light up

Because of the way that I mounted the cargo nets, I had two extra special plastic “mushroom” washers. I drilled ¼ inch holes in their middles and put them on the walls where a panel bolt already existed.

Here’s a mushroom washer in place of a wall panel bolt



From these, I hung some battery-powered LED lights that have a convenient hook and work not only as a flash light, but also a flood light. One is at the foot of the bed, by the slider and the other at the head of the bed, on the opposite side.

Here’s a mushroom washer holding a cheap, but awesome LED light

__________________
---
2012 NCV3 - 21 mpg (flat, climbing, descending, city, hwy mix...but only if I keep my foot out of it!)

My videos --> http://www.youtube.com/patrel

My music ---> http://www.reverbnation.com/kaleidoscopesundae
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