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Ae you sure the rattle is coming from that location?

Maxxair has a kit to eliminate a rattle between the rain shield and the cover. I had the rattle and their kit fixed it. Just two "U" channel pieces of rubber you put on the rain shield side panels.
 
Discussion starter · #43 ·
Ae you sure the rattle is coming from that location?

Maxxair has a kit to eliminate a rattle between the rain shield and the cover. I had the rattle and their kit fixed it. Just two "U" channel pieces of rubber you put on the rain shield side panels.
I think my rattle is from the trim piece, but I could be wrong. I'll check out that rattle kit though, couldn't hurt to put it on.
 
Discussion starter · #44 ·
Hi,
Did you notice any kind of hit on you mpg with the Cooper AT3?

I have them on my Tacoma and really like them.
I wouldn't know, I put them on my van the second day I had it. I think others have reported a 1-2 MPG drop. I love the AT3, very quiet and not as aggressive as a KO2. A friend of mine loves his KO2's and another friend says his are too loud.
 
Discussion starter · #45 · (Edited)
Today I installed an intermediate door stop from Norton Fab. My main reason is so I can open the door just halfway when getting my daughter in her car seat. And it'll be nice to crack it for fresh air but maintain some privacy when hanging out. Very nice product and easy to install. The last photo shows where the door stops and the van is parked on an incline.

http://www.nortonfab.com/?product=sprinter-van-door-stop

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Discussion starter · #47 ·
I made some simple headrest covers with a pocket and some molle style webbing straps. Keeps things like a flashlight, Swiss Army knife, tire pressure gauge etc. from bouncing around in the plastic storage area. Might look into making a universal seatback pocket system that fits the transit seats. And that's a trash bag I made too, because I have a toddler...

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Discussion starter · #48 ·
Today I got my foam mattress cut to fit the contours of the passenger van plastic trim. I bought a queen size 60"x80" (open cell firm foam) from our local mattress shop. Cut it down to 75". I have a big fabric saw that worked well on the foam. I've heard electric carving knives work too. Then made templates for the curvy pieces and made a zippered cover.

The bed frame is back from the powdercoater and will get installed tomorrow. Will post updates once it's in.

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Man - if you weren't in California, I would totally get a case of beer and come over to at a minimum use all of your tools. I will be doing the same thing with a foam mattress, but for my build I will need to do it in three horizontal sections. That's a lot of cutting and sewing to do by hand.

Looking great though!
 
Discussion starter · #50 ·
Picked up our van from Brent at Ruhne Racing today and our bed is done! Glad the mattress I cut fits. Plenty of room to store bikes underneath. I can't sit up fully but that's not my main concern. I think the bed rails are at 34", which puts the mattress at 39". 28" of head room.
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Discussion starter · #52 ·
very nice ! I chose the med roof too, you just showed me a 34in high bed is do-able and not as tight as I was afraid it could be !
Thanks. I lost a bunch of room up top due to the headliner, but that's what you get with with a wagon. I prefer the airbags and factory seats for my kids. I've thought about removing the headliner in the rear section (to increase space), but cannot find a way to create my own slim headliner and allow the airbags to deploy without issue. I'll leave it alone for now. In a perfect world, Ford would offer a crew van with rear airbags. Maybe someday.
 
Discussion starter · #54 · (Edited)
Made some rear door handles so I can close the doors from the bed. Used 1" webbing, a bar tack stitch and then a steel grommet. A friend added a rivnut and bolt.

If anyone needs some, I have webbing and the capability to press grommets.
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On the cargo the bottom bolt is exposed, I wonder if that could be used to hold the webbing?

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Discussion starter · #56 ·
On the cargo the bottom bolt is exposed, I wonder if that could be used to hold the webbing?

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I don't see why it wouldn't work, as long as the bolt and grommet spacing are similar. If not, then punch a hole in the webbing, use a washer and hope for the best. Size 2 grommets have a 3/8" hole when set.


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Discussion starter · #58 ·
Forgot to mention that Brent at Ruhne Racing also installed our swivel seat for us. I bought it from TransitAccessories.com. We didn't need to add washers or cut the plastic shroud. It did rock back and forth a bit but I added four of the adhesive magic sliders on the corners of the base. Seems sturdy now.
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Where does one acquire good webbing from? Home Depot only had super thin stuff for hanging HVAC?
 
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