[Knarfly]

My initial build was a minimal bed that could be removed to replace seats back to stock. The longer I had the van, the more I realized:

• I did not convert it often, as my mattress was heavy and hard to store
• The space underneath the bed was too small and hard to use
• I became more comfortable veering from the idea of returning to stock

I stumbled upon Vandoit and really liked their builds so modeled my own after theirs. Their LIV model uses a manual hydraulic lift to raise and lower the bed, which I really liked. No need to run power, and additional clearance for bikes when needed. I was also lucky enough to find a bedslide on craigslist that fit perfectly. Their DO model allows for beds to fold out of the way and be reconfigured. I eventually arrived on a combination of the two. I started by modeling the side cabinets and bed base. Using 15 series extrusion, I also mocked it up using 2x2s to verify my CAD. The goal was to order cut to length and tapped so it could be assembled as a kit.

Initially I had planned to run lateral extrusion and U-bolt to the original seat mounts to create mounting points for the bedslide, but changed to using ¾” ply as a cheaper temporary setup. I removed some material and added some kaizen foam in non-structural areas to hide tools or other items.

I had a solid bed frame designed but worked on the idea to split it in the middle so each half could fold out of the way. I added an overhead rail with some supports to hold movable/removable shelves, a TV, lights, as well as the bed halves separately.

I replaced my heavy memory foam mattress with two tri-fold cot sized mattresses. I can configure a near-queen E-W, or set-up just half to be a cot size, although I will need to add an extension. There were some dimensions I changed on the fly and will need to adjust to have my halves fold down straighter, they can also fold up when the hydraulics are in the lower position. The intention was to allow the option for the kids to sleep below the bed on the bedslide when needed. When in Queen E-W position the two halves are supported by braces which get stored under the bedslide when not in use. The hydraulic has a 16" stroke.

For electrical I used a Goal Zero Yeti 1000 and Trigger six shooter controller.
I reached a usable state and progress slowed. Still to do is finish out the side cabinets for usable storage, finish wiring, probably add some sort of heater, and countless other things.

Also added:

• Upgraded jumper seat to quick release
• Replaced carpet with sheet vinyl
• Maxxair
• Thinsulate insulation in ceiling
• Custom Extrusion roof rack
• OVS 270 degree Awning
• Flatline Van Side Ladder
• Passenger side swivel
• B-Pillar Lagun Table

Cheers!

 

[takedown]

Nice job!

Could you share details on the manual lift?

Could you also explain what you meant by using wood instead of the u-bolts to attach the structure?

 

[toadwbg]

We’re a source for the 15 series aluminum extrusion cut to length?


Sent from my iPad using Tapatalk

 

[Knarfly]

Nice job!

Could you share details on the manual lift?

Could you also explain what you meant by using wood instead of the u-bolts to attach the structure?

It’s a manual hydraulic lift that you find on some work benches. Dyna-lift is the manufacturer I believe.

I still used U bolts, I just meant instead of extrusion I used a sheet of plywood. I ran the U bolt under the seat bracket, and then used a piece of aluminum as a bracket to clamp down the plywood.

 

[Knarfly]

We’re a source for the 15 series aluminum extrusion cut to length?


Sent from my iPad using Tapatalk

I found Tnutz to be the cheapest for cut portions, but 80/20 and Faztek both will cut specified sizes I believe. Of course it’s cheaper to get a big stick and cut yourself if you have the means.

 

[gmoneda]

That looks great. You mentioned passenger van . Did you disable the side airbags?
Like the look and design. The foot rest for the roof is neat too.
Nice work.

 

[Rotor]

Looks great! Are the upper cabinets supported by any other means than the visible overhead 80/20?
Also, how do you like the OVS awning? I have always like the idea of the batwing type awnings, but wondered about how easy they are to setup on a high or mid roof van.

 

[Knarfly]

That looks great. You mentioned passenger van . Did you disable the side airbags?
Like the look and design. The foot rest for the roof is neat too.
Nice work.

Thanks. No the airbags are still enabled. As long as it’s not built into the window cavity it will allow them to deploy. VDI says their design has been approved by Ford, so I felt comfortable following suit in a similar regard.

 

[Knarfly]

Looks great! Are the upper cabinets supported by any other means than the visible overhead 80/20?
Also, how do you like the OVS awning? I have always like the idea of the batwing type awnings, but wondered about how easy they are to setup on a high or mid roof van.

Thanks!
No just the 2 brackets on each shelf that attach to the visible overhead 80/20.
I really like the OVS awning. I need a step stool to set it up, but it’s held up well in some wind even without the support legs. Provides lots of shade. Setup in 5-10 minutes and same for stowing it. I bought mine from CampSaver which usually has a 20% discount although it took a few months to get from back order.

 

[dhfu624]

...
I started by modeling the side cabinets and bed base. Using 15 series extrusion, I also mocked it up using 2x2s to verify my CAD. The goal was to order cut to length and tapped so it could be assembled as a kit.

I would be interested in learning more about your side (wheel well) cabinets. I plan to use a three panel platform whenever I switch to touring mode and just screw them across the side cabinets. Otherwise, I won't be carrying the platform pieces with me on a daily basis.

I am debating how to design around my rear AC because my use case is more for a daily driver/touring vehicle. I still need the AC vents for the 2nd/3rd row of seats, especially for the Texas heat. I also want to pre-order a custom 8020 set of cabinets that I can bolt into place. How did you end up installing the frame? Rivnuts in the side and floor of the van?

 

[Knarfly]

I would be interested in learning more about your side (wheel well) cabinets. I plan to use a three panel platform whenever I switch to touring mode and just screw them across the side cabinets. Otherwise, I won't be carrying the platform pieces with me on a daily basis.

I am debating how to design around my rear AC because my use case is more for a daily driver/touring vehicle. I still need the AC vents for the 2nd/3rd row of seats, especially for the Texas heat. I also want to pre-order a custom 8020 set of cabinets that I can bolt into place. How did you end up installing the frame? Rivnuts in the side and floor of the van?

My first bed was a rail I installed with rivnuts behind the trim, and removable panels. I was able to use a couple of those mounting points as well as the rearmost seatbelt anchor points to secure the frame. I also designed it to use the D-Ring anchor above the wheel well, but didn't end up using it yet.

 

[Stadblaster]

Great job. For the 80/20 ceiling skeleton, what does it mount to?
Thanks

 

[Knarfly]

Great job. For the 80/20 ceiling skeleton, what does it mount to?
Thanks

I installed rivnuts into the ribs where the gray plastic headliner plug typically goes.

 

[gmoneda]

I hope I am wrong but in the transit airbag video the airbags come down from the windows but the whole headliner is allowed to move out to make that

 

[gmoneda]

Thanks. No the airbags are still enabled. As long as it’s not built into the window cavity it will allow them to deploy. VDI says their design has been approved by Ford, so I felt comfortable following suit in a similar regard.

I hope VDI is right, but based on the videos I have seen, yes the airbag comes down the window, but only after the headliner has moved out of the way by quite a bit as seen near the 4:30 mark.

They may still deploy have other implications for what is mounted around there. At one point there was official mention of a storage area add on for upper area of passenger van but it never made the market.

Don't mean to be a debbie downer, but a small accident that does deploy that airbag could be made a lot worse if is projects other objects. Regardless of VDI if aftermarket your insurance could deny claims due to that, leaving you on the hook.
I so want there to be safe upper storage passenger van options, but I would remain very skeptical IMHO. Does VDI have a video?

 

[Knarfly]

I hope VDI is right, but based on the videos I have seen, yes the airbag comes down the window, but only after the headliner has moved out of the way by quite a bit as seen near the 4:30 mark.

They may still deploy have other implications for what is mounted around there. At one point there was official mention of a storage area add on for upper area of passenger van but it never made the market.

Don't mean to be a debbie downer, but a small accident that does deploy that airbag could be made a lot worse if is projects other objects. Regardless of VDI if aftermarket your insurance could deny claims due to that, leaving you on the hook.
I so want there to be safe upper storage passenger van options, but I would remain very skeptical IMHO. Does VDI have a video?

Yep agreed, very important to consider airbags as that is one of the main reasons to use a passenger van. Thank you for linking the video. VDI doesn't have a crash test video that I'm aware of but they are an approved Ford dealer / upfitter, claim Ford has approved their design, and they also sell hundreds of vehicles. I am not them, and have only emulated some of their design aspects and I am not making the same claims. They also have another model that provides a full internal skeleton, that would also allow the airbags to deploy.

The upper shelf is only connected at the front and would be able to move out of the way to provide clearance in the event the airbags deployed. It is not to be a significant weight bearing shelf. I also travel with a cargo net partition separating the passenger area from the back to prevent any further projectiles, and any other items are tied down. In any case when you consider alternatives such as an RV where seatbelts are for decoration I feel confident this is a safer alternative for traveling and camping with my family.

There are other soft sided alternatives to overhead storage such as the Adventure Wagon Mule Bags, or some Duffel bag hacks. On this forum I have seen the fabric/plastic trunk organizers installed vertically as well. I'm not trying to sell anybody on my design choices, only you can make that decision for your comfort, safety, and storage. Cheers!

 

[SION1771]

I actually chose Adventure Wagon over VDI because the passenger van requirements and the airbag issue (and too many windows). Sure, you can install soft bags or whatever, but there's still an explosive airbag behind them. Rolling my van will disturb the contents of the overhead area more than I'd like in the case of an airbag deployment.

There are other soft sided alternatives to overhead storage such as the Adventure Wagon Mule Bags, or some Duffel bag hacks. On this forum I have seen the fabric/plastic trunk organizers installed vertically as well. I'm not trying to sell anybody on my design choices, only you can make that decision for your comfort, safety, and storage. Cheers!

 

[Showtime3]

You can see how the airbags deploy in the video below. When they go off they fold down and towards the window. So it would be a non issue for the uppers

 

[SION1771]

You can see how the airbags deploy in the video below. When they go off they fold down and towards the window. So it would be a non issue for the uppers

That's a great video - thank you for sharing that! Welcome to the forum.

 

[Stadblaster]

thanks. What pull out did you use looks like it fits perfect