Sprinter build thread

[breakdirt916]

desert southwest vehicles are a nice relief to work on!!

if not for the lack of snow/salt, I feel like the dry weather also keeps them relatively intact

[Paul_E_D]

OK, after a couple days of intensive electricity study, I have the solar system figured out and humming right along. After that I pulled the overhead cabinets on one side where my "closet" and surf rack will go. It was a bitch to get out, and the headliner was cut out behind the cabinets, so I now have a clean slate to build out that side.

I was able to trace some wiring that wasn't functioning before, and I discovered an empty fuse holder. So that's why half my lights weren't coming on. I also discovered that the van was insulated at least a bit.

I measured up the hole in the headliner, the closet dimensions, and headed to home depot for some 1/2 inch birch plywood. I had them do the big rips and cuts to save me the hassle as I only have rudimentary wood tools. When I got home, I had a bit more cutting than expected left to do. But I essentially hung siding where the cabinet hole was.

Next I used a big piece of cardboard to make a template for the first side of my closet. The roof and walls are anything but simple lines, so this was really essential to my design process. Once happy with the fit of the cardboard, I traced it on one of the pre cut pieces of birch, and boldly cut it with my handheld jigsaw. Brought it up to the van and boom, it fit right up the first time. With one half of the closet in place, I could start to see where exactly everything should go. Clothes bar, removable shelves, and cutaways for feng shui and whatnot.

I can't show you because my camera on my phone died. Gah!!!

[Paul_E_D]

OK, EPIC design/build weekend winding down. I finished templating, cutting, fitting, adjusting the closet walls. Once in place a few cool design ideas came to me. A slide out shelf that functions as a laptop station, dining table, and with the "window" I cut in, it opens to the sofa/bed area to act as a night stand or even TV stand. Multi-function FTW! It has a cool retro look too. The window is reminiscent of a 60s televising set.

After I was satisfied with my work, I pulled it all down to finish it up, sand and urethane. It's all drying waiting for final install. Since I'm not getting to access the wall behind it after it's all in place, I ran some wiring for updated LED lighting that is in the future plans.

I wish I could show you my work, but I still have no camera...

Overall, I'm really pleased with my design work. A little less pleased with my woodworking skills, but hey, this is really the first project I've done that is ALL custom work and complex shapes. Also, it's a surf van, not the taj majal!

Can I just say that working with veneered plywood sucks balls! I'm glad that's over with... for now.

[R7]

Can I just say that working with veneered plywood sucks balls! I'm glad that's over with... for now.

It's just not the same without pics..haha

Tips for cutting veneered plywood, a steady hand, a sharp skill saw/jigsaw blade, and most important, a sharp razor knife. The trick to making a nice cut with veneer, is to not actually cut the veneer with the saw. Take a thin straight edge, lay it on the wood and cut the line with the razor knife. It's easy for straight cuts, takes a little more time and creativity for curved cuts. The steady hand comes into play with the saw, as you need to be carefull not to cut into the line you just scored with the knife

[Paul_E_D]

Now you tell me. :slapshead: I just tore it up and didn't worry too much about the edges. Was all complex curves anyway. Not sure I could follow a line!

And I can't friggin believe my camera died for the climax!

[Garandman]

Don't worry, your Sprinter will become self-aware soon and take pictures itself.

[Paul_E_D]

Judging from the wiring harness under the driver's seat, it already IS self aware!

[Garandman]

In Soviet Russia, Sprinter drive you!

Saw this in Boston traffic last week, stock Econoline next door.

[Paul_E_D]

I want that rear bumper/gate setup, but it's 3K at least.

[snwbrdr435]

I would guess around 2k 2.5 tops

[Paul_E_D]

ok 2.5K, still too much for me.

Today I took all the pieces and put my van back together. I can't show you yet, but it's friggin awesome. LOL. Seriously, I give myself an A- for design. The way the closet/shelf/laptop station/nightstand works is just flawless. The bed/sofa conversion is spot on as well. SUPER comfy with the Ikea egg crate foam mattress. Easy to sleep for one, or two. Super roomy and comfy as sofa.

I still have to road harden it a little more, and tie up some loose ends, but I can at least confirm that it's going to be a SWEET setup. I get a B- for craftsmanship though. I made a few mistakes.

Next up, replumb water system, then build the surf rack.

[rolker]

Wow, can't wait to check it out! When are taking her to Loudon?

[typeone]

awesome progress, can't wait to scope this thing out!

[Paul_E_D]

OK, no more teasing. Phase 1 of my sprinter upfit revealed!!!


The shelving unit is a multi function unit. With the shelves removed you can hang leathers or wetsuits.


The sofa is super roomy and lays flat to make a double bed.



There is both 12v and 110 power available at this station via the solar/battery system. The removeable shelves and windows make it functional from all directions.

[caddydaddy]

Damn, that is awesome!

[loudbeard]

Looking good indeed! We talked a bit about the now defunct idea of a roof rack, I also can build steel bumpers and swing out tire carriers if you decide want to go that route.

[Paul_E_D]

Looking good indeed! We talked a bit about the now defunct idea of a roof rack, I also can build steel bumpers and swing out tire carriers if you decide want to go that route.

We must talk. Will you be at NYST this weekend?

[loudbeard]

Yep, I'll be there

[snwbrdr435]

Looking good indeed! We talked a bit about the now defunct idea of a roof rack, I also can build steel bumpers and swing out tire carriers if you decide want to go that route.

Ooooo I could possibly use these services as well if your interested...

[Puppet]

This thing is awesome. Looking forward to seeing it this weekend!

[Paul_E_D]

OK, I'm getting there. tonight I added a 6 circuit negative bus fuse box and wired it to the load circuit with a 15 amp fuse on the positive lead.


rewired the house lights so that they are on a one circuit and not tapped into the water pump circuit, rather back to the fuse box. I also wired a 12V 3 outlet panel to the fusebox. each with a 15 amp fuse. I updated half of my lighting to LED bars, but kept half of the incandescent lights. I can't quite get cozy with LED lighting. I got "warm white", but it still looks flourescent to me.


The solar system and batteries seem to be working fine. BUT, I still get intermittent errors and very rarely, the inverter won't power on without a few tries. I suspect a weak ground somewhere, but I have cleaned and tightened everything I can find.

[Garandman]

Interesting take: Extreme Boondocking and the TP Factor

Guy has spent up to 2 1/2 months living in the camper.

[Paul_E_D]

OK, some setbacks and some progress. I got a little cocky with the use of the inverter power for tools. I plugged in a vacuum and blew the inverter. I tried changing the fuses, but it is smoked. It's about 300 bucks to replace with equal, or 400+ to upgrade.

I found my "closet" walls to be a bit floppy only secured at the top and bottom, so I tied them together front and back just under the bottom shelf. It means I will have to lift my leathers over the board in front to hang them, but it is MUCH more stable.

Next, I got some pex tubing to re-connect the water tank to the sink via the shurflo pump. I put the fuse in and the pump pressurized the system. I had to address a leak, but I got that taken care of. Now the pump click every second or so. There's no leak that I can find. It's not even really running, just clicking on and off instantly??

[loudbeard]

Does the motor have a capacitor or is it DC?

[Paul_E_D]

DC