[traxatmsu]

Nice Santa Cruz

 

[markley]

Finally managed to find 2 days without rain and when I was available to work on the van... time for the MaxxAir fan and the solar panel support !

I made a template to drill 4 pilot holes so I know where to cut with the jig saw from the top. Yes the template was "CNCed" to match the roof curvature.. totally pointless but it was fun to do and I had (lots of) time to waste while it was raining.

Then the "oh my god am I really doing this ?" moment..

Then sanding, drilling, painting, cleaning...
While it was all drying I regrouped all the parts for my roof rack and installed it. Mad those out of 3mm aluminum : waterjet cut, bent, then powdercoated.

And finally installed everything, then some sealant..

The rain started again so I had to stop just before I drilled the holes for the solar panel cable glands.. I'm working on the solar panel cables for now, then I'll keep going on the roof insulation.

Awesome work! So did you also make the support brackets for the solar panels? I have 80/20 on the way and have been wondering how I am going to attach panels. I really like how you did yours!

Sent from my SM-G920V using Tapatalk

 

[Ben]

Awesome work! So did you also make the support brackets for the solar panels? I have 80/20 on the way and have been wondering how I am going to attach panels. I really like how you did yours!

Sent from my SM-G920V using Tapatalk

Thanks !
All the brackets (towers, angles, solar panel supports) are custom made, I only bought the 80-20 tubings and the t-nuts.

 

[fargy483]

**** yea!

 

[cajohsnt]

Love the build! I'm working on buying a Transit (maybe tomorrow) and am digging all the inspiration here.

 

[Gstarbuck]

Interested

Ben, I really like your build. I’m slowly deciding on a layout for my van. I keep coming back to your build. It reminds me of the layout in the VW Westfalia's that were the gateway vehicle to eventually buying a Transit. I haven’t played with CAD programs much and don’t have a CNC router (yet), but I do like to learn new things.

Which leads me to some questions -

Now that you’ve had time to use the van, how do you like the layout? Would you change it much?

Do you think a cnc router kit like the maslow cnc would work well enough to make a build like yours?

Would you be willing to share the CAD files to help me get started?

Thanks

 

[MrsFishie]

Ben, your build is very impressive. Been looking through endless posts looking for ideas for our van, and haven't yet seen a raised bed that folds out like yours. Thanks for sharing. Just amazes me the number of ideas out there all in such a small space!

 

[Ben]

Now that you’ve had time to use the van, how do you like the layout? Would you change it much?

Well I have to say I really like the layout as is, the main concern I could think of is I the lack of dedicated space for skis.. small skis are OK the can be stored sideways in the bike compartment, but anything more than 180cm won't fit..should have thought of it (all my powder skis are over 180cm...).

I didn't work on the camper during the winter so I've been using it as shown in the last pictures and it was great. However during the summer I'll slowly continue building the rest of the conversion :
- single rear seat instead of double, to give more space for a fold-out table on the driver side (something like that, but obviously larger..) + give room for a kitchen cabinet on the passenger side.
- overhead cabinet on the driver side
- eventually a window on the sliding door...
- improve storage in the garage compartment.

of course all of that supposes I win the lottery...

Do you think a cnc router kit like the maslow cnc would work well enough to make a build like yours?

I don't see why it wouldn't work, at first sight I would be concerned about machining precision but I'm not familiar with this CNC so it has probably been addressed... I've build my machine from scratch for the purpose I had. The CNCRouterParts kits are a great choice too, closer to a commercial machine, but it's more pricey..

Would you be willing to share the CAD files to help me get started?

My CAD files are a mess only I can kinda go through, the CAD is one thing but I also made some changes directly in the g-code on-the-fly .. and keep in mind that most of the cabinet parts had to be manually trimmed to fit the curves in the van.. my files wouldn't be of much help, trust me you'd better start from scratch !

 

[Ben]

Ben, your build is very impressive. Been looking through endless posts looking for ideas for our van, and haven't yet seen a raised bed that folds out like yours. Thanks for sharing. Just amazes me the number of ideas out there all in such a small space!

Thanks !
Yeah the bed is different from what we usually see.. it works great !

 

[swellguy]

Got a little busy and had fun with the CNC this past week-end.. it's a start !
This cabinet will have some storage space for the clothes (top), and the bottom part will house the battery (bottom front) + 3 drawers (above the battery) + the electrical panel (above the drawers) and 2 compartments with doors just behind that. The large opening in the rear is for bike storage, no cabinet there even tough there is a panel there against the rear door for mock-up purpose.
And this full cabinet will also support the left hand bed rail...

Still need to make the front panels + some structural parts, and decide how and where I attach it the the van (Ihave a few option, I have to chose one..)

Everything is made out of 1/4" and 1/8" plywood (baltic birch).
I didn't document how I did the ceiling but I still have to take it out to install the lights and apply some varnish anyway.. will take pics then !

Man, the craftsmanship on those cabinets is a work of art. I'd love to have access to a CNC and laser cutter. Maybe there'll be consumer grade versions of that some day or I'll get a rich friend with access to one!

 

[Telehead]

Looks like you are a ski builder????

 

[Hein]

Awesome work! So did you also make the support brackets for the solar panels? I have 80/20 on the way and have been wondering how I am going to attach panels. I really like how you did yours!

Sent from my SM-G920V using Tapatalk

We developed and sell towers: https://www.ebay.com/itm/132465789379
And also the tabs to support the panels: http://www.ebay.com/itm/141878685652

Very nice design and CNC work on the cabinets. Neat how you removed mass by hogging
out the recesses. Tabs/notches are slick way to assemble. Curious about the material?

 

[Ben]

Looks like you are a ski builder????

Indeed I am.. or was.. because building the van takes a lot of time

We developed and sell towers: https://www.ebay.com/itm/132465789379
And also the tabs to support the panels: http://www.ebay.com/itm/141878685652

Very nice design and CNC work on the cabinets. Neat how you removed mass by hogging
out the recesses. Tabs/notches are slick way to assemble. Curious about the material?

Yep, let's say I was inspired a lot by your products, not that they are expensive but I have access to a waterjet CNC and fully equipped metal shop for bending stuff... so I tweaked them a little bit to fit my needs.

The cabinets are made from 1/4" and 1/8" baltic birch plywood, I've cut the different layers of each panel one at a time and then used my ski press for the assembly. Final panels thickness vary from 1/2" to 1" depending of where I needed strength. it took time but the result is definitely worth it !
The dado assembly thing comes from a previous job where I designed private aircrafts interiors, I've tried to use the same kind of process but I obviously can't make my cabinets from those expensive aircraft carbon honeycomb panels we used back then.

 

[Haulin' Gas Adventures]

I’m going to PM you Hein regarding some mounts using 40 mm extrusion for a roof rack.

 

[swellguy]

So, you don't use 80/20? I must say, I prefer your workmanship, but I noticed that many aircraft interiors in commercial aircraft are done with 80/20.

 

[surly Bill]

Indeed I am.. or was.. because building the van takes a lot of time


Yep, let's say I was inspired a lot by your products, not that they are expensive but I have access to a waterjet CNC and fully equipped metal shop for bending stuff... so I tweaked them a little bit to fit my needs.

I used to build snowboards. I'd LOVE to have a tabletop CNC machine like that, maybe I'll build one, too! In the 90's, through our company I worked with Abrasive Engineering & Manufacturing to make the first CNC Timesaver sander, which we used to make our cores. I was pretty green about business, I helped them design it, providing most of the required specs, and they CHARGED us for the machine, and then patented it and added it to their line. Now, I would have the prototype for free, and either bill them for my time or get a piece of the profit from subsequent machines sold, or both. I also figured out a big scissor press with 7' long air bladders and heated forms for laminating the snowboards. No cap construction or prepreg glass for us!

 

[Ben]

So, you don't use 80/20? I must say, I prefer your workmanship, but I noticed that many aircraft interiors in commercial aircraft are done with 80/20.

You're right, commercial aircraft cabinets use aluminum profiles pretty often, but not only.. and it depends of the cabinet manufacturer actually, they all have their receipe.
However on private aircraft there is no way we could use aluminum profiles, everything is visually top notch with wood trims and veneers everywhere, and leather, and shiny stuff... even in areas the owner probably won't ever look at. Almost everyting in the finishing process is manually and custom made, it's pretty crazy !.. and expensive... but when you buy a priate aircraft money is not a real concern I guess...

 

[swellguy]

You're right, commercial aircraft cabinets use aluminum profiles pretty often, but not only.. and it depends of the cabinet manufacturer actually, they all have their receipe.
However on private aircraft there is no way we could use aluminum profiles, everything is visually top notch with wood trims and veneers everywhere, and leather, and shiny stuff... even in areas the owner probably won't ever look at. Almost everyting in the finishing process is manually and custom made, it's pretty crazy !.. and expensive... but when you buy a priate aircraft money is not a real concern I guess...

Yeah, I've been on a G5, a Citation and a BBJ, and they have amazing finish work. Was on a commercial flight once, and noticed 80/20 on all the corners.

 

[Ben]

Back into building cabinets after a year without touching the wood tools...
I'm working on my kitchen cabinet (will take pics tomorrow) since I managed to find a used (meaning "cheap-ish") fridge at a local truck-A/C garage... + I brought back a small sink and a nice faucet + 12V pump from my brother's (he built a camper a few years ago but sold the van back empty.. and have been keeping some of the interior parts in his basement for too long.. according to his GF .

Anyway, so I found a fridge, a Dometic/Waeco CR50. It's not pretty, it's been used a lot but it works (the seller gave me the test reports), it's exactly the size I was looking for (standard truck size) so when money will be available (it might happen some day... hopefully...) I should be able to buy a newer model and just replace the fridge in the same cabinet...

I've built a cabinet prototype I used a few weeks to check if it was practical and if it was what I expected (before I got the fridge), and after a few new/different approches I built and installed the new, unfinished (yet), kitchen cabinet in the van yesterday with the fridge !

The fridge has been running all day, when I got back home this evening the inside was cold, the freezer had some ice build up, but the thing I noticed is how hot the rear of the fridge is ! it's crazy ! I have a couple grilles close to the compressor for good venting but I don't know if it's gonna be enough, I might add computer fans to increase airflow, luckily I have room for that on one side..

Do you guys who have similar fridges noticed how hot the compressor area gets ? I guess it's normal but I was not expecting that much heat. I won't complain about it in winter but in summer the van interior was already warm enough for me
Regarding the noise, it's OK, not perfectly silent but ways quieter than the Webasto heater in winter... about the same noise as the Maxxair on #2 setting I'd say.

Having the fridge making so much heat made me think about power consumption. The heat is generated by something.. and that something draws power from my battery. I don't have any electrical system monitor such as a Bogart or Victron yet, but I'm thinking of it.. or at least I'm thinking I should have a way of checking how much energy I use !
Bogart and Victron seems to be the best choices and definitely are good products, but they're pricey ! I've heard of something ways cheaper but that could probably give me the basic data I need to evaluate my energy usage : the "Watt's Up" or "Doc Wattson" (https://www.rc-electronics-usa.com/ammeters/rv-battery-monitor.html)

Anyone has tried this battery monitor ? It doesn't seems to be wired on a shunt close to the battery (unlike the Victron or Bogart) so I'm wondering how accurate it is. It's definitely a basic product but it seems to be delivering the data one would need to check his energy consumption...

 

[Eiko]

It doesn't seems to be wired on a shunt close to the battery (unlike the Victron or Bogart) so I'm wondering how accurate it is. It's definitely a basic product but it seems to be delivering the data one would need to check his energy consumption...

Their website says the shunt is internal: "The black wires are connected inside the meter across a built-in current shunt. The shunt is where the current flow is measured."