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Sprinter build thread

  1. #676
    Super Moderator TheIglu's Avatar
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    Re: Sprinter build thread


    Probably run better if y'all put diesel in it, not gas.

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  2. #677
    Lifer snwbrdr435's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by TheIglu View Post
    Probably run better if y'all put diesel in it, not gas.
    Hah funny you mention that one of my friends was on a cross country trip in another friends sprinter. Middle of Iowa and they filled the tank with gas then drove 50+ miles. It basically destroyed the fuel system and motor as well as their diesel heater and cooksurface. They spent the next 6 months of the trip stopping at one Mercedes dealership or another trying to get things fixed. I think eventually they needed to put in a complete new motor and fuel system.....

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  3. #678
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by TheIglu View Post
    How many gallons in the tank?
    26.4. 100 liters. Reserve light comes on with 2.5 gallons/ 10.5 L.

    My first recorded tank was 22.6mpg. Lots of people do better but that’s great for city use.

    Insulation is shipped can’t wait, it’s loud on the highway.

    One of our guys put gas in a diesel Cruze. $1,700 repair.

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    Last edited by Garandman; 06-08-19 at 11:08 AM.
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  4. #679
    Posting Freak joeswamp's Avatar
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    Re: Sprinter build thread

    A friend of mine worked as a driver for Domino's Pizza back in the 1980s. This was back when Domino's actually owned all the delivery cars -- they were painted in a crazy Domino's paint scheme.

    He told me that as a fuel-saving measure, the company bought diesel Chevettes to deliver all the pizzas. He told me that the pizza drivers would fill them with gas more than once per month, and the repair costs were beyond crazy. I think they switched back to gas in less than a year.

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  5. #680
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Still waiting on the insulation and some small parts (like the rear door upper striker plate, notorious for falling off) so continued inspection and cleaning.

    These diesels sometimes develop injector seal leaks. The name for the condition is overly dramatic, but it does create a mess and requires removal of the injectors. So wanted to check for myself: so far (147,000 miles) so good.





    Also cleaned up some of the metal surfaces that have what seems like varnish on them.

    Hit 400 miles on this half tank so seems to be doing better mpg-wise.

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  6. #681
    Posting Freak caddydaddy's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by Garandman View Post
    These diesels sometimes develop injector seal leaks. The name for the condition is overly dramatic, but it does create a mess and requires removal of the injectors. So wanted to check for myself: so far (147,000 miles) so good.
    Ah, the black death! haha! Fortunately, at 222,000 miles the OM642 in my Jeep hasn't needed injector seals yet. I keep an eye out for any signs of leakage though.

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  7. #682
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    I’m getting random glow plug codes. They are notorious for one or more sticking in the head and breaking. I’m probably going to bring it to a shop (one recommendation is Banchworks in Providence) who does it all the time, and git ‘er done while its warm. Runs great otherwise so I’m assuming the injectors are bueno.

    Cargo floor was pretty rough, unsurprisingly.



    Painted it a medium gray, with textured deck paint.


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  8. #683
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Ran into a “Gotcha” while getting ready to start installing L track. Bought some 1/4-20 flat head bolts and they stood proud of the countersunk holes.

    The deal is there are different standards for flat head screws. The aircraft industry typically uses a 100 head: that’s what L track is drilled for. Most standard screws are 82.

    The 100 1/4 bolts are usually 1/4-28 (UNF) versus 1/4-20 (UNC). Turns out 1/4-28 Rivnets are not as widely available as 1/4-20.

    Still evaluating but I think I’m going to buy an 82 Countersink and face the holes so I can use standard screws. There may not be enough material to drill down that much.

    Update: ordered 100 1/4-20 from McMaster.

    FYI Metric standard is 90

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    Last edited by Garandman; 06-10-19 at 05:53 PM.
    1975 BMW R90/6 | 2008 Triumph Tiger 1050 ABS | 2009 Honda CRF100F | 2009 Yamaha TrailWay 200 | 2012 Yamaha WR250R | 2016 Honda CB500FA | 2016 Suzuki GSX-R750

  9. #684
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Sorted through the screw issue: ordered 100 1/4-20 flat head screws. Also using the heavy wall threaded inserts from McMaster.

    Finished putting in the 20 Nutserts to replace the rivets used to hold down the floor. Putting down two layers of closed cell foam, then the OEM floor panel.

    I’d like to put down some of the coined rubber covering over it, but haven’t found any place that has a wide-enough roll.


    Probably going to use flanged track on the sidewalks, and tie the wall panels into it. This is the test fit.


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    Last edited by Garandman; 06-12-19 at 09:04 PM.
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  10. #685
    Soul Rider Paul_E_D's Avatar
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    Re: Sprinter build thread

    careful building up the floor too much. The insulation doesn't do much, but the lost headroom is a real drag.

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  11. #686
    Lifer Chippertheripper's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by Paul_E_D View Post
    careful building up the floor too much. The insulation doesn't do much, but the lost headroom is a real drag.
    What replaced your van?

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  12. #687
    Soul Rider Paul_E_D's Avatar
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    Re: Sprinter build thread-(Pictures are back!)

    A longer van. With a full winnebago in it...

    Sent from my SM-G930V using Tapatalk

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  13. #688
    ^ It's my bike and my car tls25rs's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by Paul_E_D View Post
    careful building up the floor too much. The insulation doesn't do much, but the lost headroom is a real drag.
    Forgive me for chuckling at you complaining about losing headroom

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  14. #689
    Soul Rider Paul_E_D's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by tls25rs View Post
    Forgive me for chuckling at you complaining about losing headroom
    Ha! well, he has the low roof van. I know he can't stand up in it anyway, but losing 4 inches is a big deal... that's what she said anyway.

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  15. #690
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Quote Originally Posted by Paul_E_D View Post
    careful building up the floor too much. The insulation doesn't do much, but the lost headroom is a real drag.
    I can’t stand up anyway but the minicell is only 0.25” thick.

    This is our fifth van and we have always insulated the floor. If for simplicity sake we say it’s a 10’ x 5’ x 5’ box, the floor would represent 20% of the surface area. Our experience is that drivetrain heat is disproportionately high in warm weather, and the floor cools down very quickly in cold weather.

    Stock there is just the thin layer of plywood and some tar paper-like underlayment.


    It didn’t seem particularly effective and didn’t fill the channels.



    We are going to fill in the channels with 0.30” foam (which does not raise the floor) then add a 0.25” solid sheet over that. Should be very effective against heat and noise. Along with Thinsulate for walls and roof, it’s the latest development.

    Still looking for a good tape to minimize thermal bridging. Have a couple to try.

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    Last edited by Garandman; 06-13-19 at 09:43 AM.
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  16. #691
    Lifer Chippertheripper's Avatar
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    Re: Sprinter build thread-(Pictures are back!)

    Quote Originally Posted by Paul_E_D View Post
    A longer van. With a full winnebago in it...

    Sent from my SM-G930V using Tapatalk
    Travato? Which model is that?

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  17. #692
    Soul Rider Paul_E_D's Avatar
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    Re: Sprinter build thread

    Yeah, it's a '19 Travato 59G

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  18. #693
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Hell of a rig!

    Although it runs great, van is throwing various glow plug error codes. Bringing it to Banchwerks in Providence, RI Monday.

    Been installing Nutserts for the L track. A lot of Nutserts. Have the 13” Astro Pneumatic hand setter and while it works well, it takes some effort with the heavy wall 1/4” inserts I’m using.

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    Last edited by Garandman; 06-13-19 at 09:26 PM.
    1975 BMW R90/6 | 2008 Triumph Tiger 1050 ABS | 2009 Honda CRF100F | 2009 Yamaha TrailWay 200 | 2012 Yamaha WR250R | 2016 Honda CB500FA | 2016 Suzuki GSX-R750

  19. #694
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Fixed spare tire hanger bolts. Old ones were twisted and frozen. Had to drill out the heads to get them off. Put Nev’r Seize on the new ones.


    Installed seat swivel. So it’s an adventure van. Small “a.”

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    Last edited by Garandman; 06-15-19 at 12:50 AM.
    1975 BMW R90/6 | 2008 Triumph Tiger 1050 ABS | 2009 Honda CRF100F | 2009 Yamaha TrailWay 200 | 2012 Yamaha WR250R | 2016 Honda CB500FA | 2016 Suzuki GSX-R750

  20. #695
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Sprinter build thread-4a6464ee-f8d9-4270-b96c-33f2906313abMore minor progress. Like most cars the textured plastic holds dirt and is hard to clean. Got a product called Spray Nine and a bristle brush - good as new!
    Attached Thumbnails Attached Thumbnails Sprinter build thread-5732f00e-7194-404d-89c5-66069f853527  

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  21. #696
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Some good progress this weekend. Removed the center console to pull out the front floor mat and clean it.


    Before.


    After.



    Installed minicell foam under the floor. Another layer went over this.


    And reinstalled the stock floor after repainting with two layers of textured deck paint. Floor is held down with 20 1/4-20 flat head screws threaded into heavy wall 1/4-20 Nutserts.

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    Last edited by Garandman; 06-23-19 at 09:10 PM.
    1975 BMW R90/6 | 2008 Triumph Tiger 1050 ABS | 2009 Honda CRF100F | 2009 Yamaha TrailWay 200 | 2012 Yamaha WR250R | 2016 Honda CB500FA | 2016 Suzuki GSX-R750

  22. #697
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Big progress yesterday. Took down the headliner, added Butyl sound deadening and then Thinsulate.

    Then worked my way back. My son cut some of the pieces for me. The stuff is so easy to work with! Light, flexible, few shots of Super 90 adhesive and it’s on. Used trimming to stuff small areas. Have a few more pieces to put up, more L track and the cladding. But the van is much quieter and will keep cool/warm a lot better.

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  23. #698
    Lifer Garandman's Avatar
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    Re: Sprinter build thread

    Picked up three 5'x10' sheets of 4mm okoume plywood today from Boulter Plywood in Medford. This will go over the Thinsulate. Should be attractive and durable.

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    1975 BMW R90/6 | 2008 Triumph Tiger 1050 ABS | 2009 Honda CRF100F | 2009 Yamaha TrailWay 200 | 2012 Yamaha WR250R | 2016 Honda CB500FA | 2016 Suzuki GSX-R750

  24. #699
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  25. #700
    Fast is contagious JettaJayGLS's Avatar
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    Re: Sprinter build thread

    Hmmm, was just looking at thinsulate...my van has a squeak I can't find...I think its a piece of polystyrene. Dammit.

    I was unemployed when building mine so I was kinda on a budget. I ruled out thinsulate because the R value is crap and its expensive, but I'm thinking a base of polystyrene and thinsulate to fill the nooks and crannies might be the way to go next time. I'll sell this before I pull the walls down to re-do insulation.

    That said, I have no intention to sell, but the pricing on these vans out here is absolutely ridiculous. Just waiting for someone in Marin to offer me $35k at a gas station. I'll go buy one on the east coast and drive it home.

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    Last edited by JettaJayGLS; 06-28-19 at 12:27 PM.
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