Kim_Marcus
Kim Possible 2004 2500 SR
Thanks for posting all the work you did. It helps.
Hey Monafly, just stumbled across your build. I'm also re-using the factory floor, but mine isn't quite as nice as yours.Here's the finished floor, showing the layout-floor brackets between the wheel wells, L-track in the forward area and front and back edges finished off with L-track.
I want to bend L-Track like this. What kind of press did you use to bend the L-Track? Thanks!Here's more on the L-track mounts for the bed platform. In one of the above pictures you can see the two L-tracks, one on the rear pillar and the other on the C (?) pillar. In order to mount them, I had to bend them to the shape of the walls.
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To make these bends, I used a the following technique. Took some care, but was pretty easy once I got the hang of how much force to apply and where. Small pieces of plastic decking protected the surface.
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After fitting for shape, I drilled holes for the Rivnut mounting.
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On the C pillar I could mount about every 6-8". The rear has a section toward the bottom where it has no support for 8-10", but is mounted securely below and above where feasible. It's not going anywhere. I was careful to mount these supports parallel, so no adjustment of the bed rail mounts is necessary when one changes their positions.
Ultimately, the L-track will support the wall coverings.
Bed was finished off with two 4" thick foam pads, covered with upholstery fabric. The bed panels are all 2' which gives 6' long bed. The rear pad (pictured) is 2' deep has the corners cut off to match the rear door contour. The other is 4'. We find it very comfortable.
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The only issue I have with them is that we usually sleep in sleeping bags and the static build-up is shocking.
I am wondering what size of 80/20 you used for side bed support. Was it 1.5” x 3”? I am hoping to use 1” x 2” but not sure if that will be strong enough.Bed panels in place.
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View from below showing the side rails and gas shocks (small black lines on the right) used to provide outward pressure to push the panels open. There's a small catch to hold it closed (shortened) for storage etc.
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Here are some shots of the side rail supports. If I was to do this again, I wouldn't use the double size 8020. It's overkill, as regular size would provide plenty of strength.
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These rails are attached front and rear to L-track via brackets for easy, no-tool vertical adjustment. I'll detail later the L-track.
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