Sprinter

02 Freightliner Sprinter 2500 long, tall with full roof rack

2009-07-20T20:51:00Z

Dan
02 Freightliner Sprinter 2500 long, tall with full roof rack

An overview of the roof rack. The gray foam by the spare covers a crossbar for tying canoes to.

2009-07-20T21:22:30Z

Dan
An overview of the roof rack. The gray foam by the spare covers a crossbar for tying canoes to.

The roof rack grating is welded to the 1x1 bar structure. This view is from the back of the truck

2009-07-20T21:05:16Z

Dan
The roof rack grating is welded to the 1x1 bar structure. This view is from the back of the truck

Us city boys set up shop where we can---my front porch

2009-07-20T21:19:17Z

Dan
Us city boys set up shop where we can---my front porch

I've removed the previous 3-way fridge and started to route L-track into the floor

2009-07-20T21:36:31Z

Dan
I've removed the previous 3-way fridge and started to route L-track into the floor

This was the pilot door and vent for the old 3-way fridge

2009-07-20T21:41:51Z

Dan
This was the pilot door and vent for the old 3-way fridge

Previous owner had only an outlet for electricity.

2009-07-20T20:31:34Z

Dan
Previous owner had only an outlet for electricity.

The 1/4" reflective foam is the standard factory insulation I believe.

2009-07-20T20:53:18Z

Dan
The 1/4" reflective foam is the standard factory insulation I believe.

My carpenter friend Danny about to install L-track into a routed slot in the floor.

2009-07-20T22:08:02Z

Dan
My carpenter friend Danny about to install L-track into a routed slot in the floor.

Dan's photo

2009-07-20T21:23:31Z

Dan

Dan's photo

2009-07-20T22:12:37Z

Dan

There are end half rounds for the L-track. They fit the width of the flanged track nicer.

2009-07-20T21:01:44Z

Dan
There are end half rounds for the L-track. They fit the width of the flanged track nicer.

There are 3 rows of flanged L-track on the walls. The flanges will hold down the padded vinyl panels.

2009-07-20T21:47:44Z

Dan
There are 3 rows of flanged L-track on the walls. The flanges will hold down the padded vinyl panels.

Dan's photo

2009-07-20T20:45:28Z

Dan

Dan's photo

2009-07-20T21:25:17Z

Dan

Dan's photo

2009-07-20T21:07:04Z

Dan

Dan's photo

2009-07-20T21:36:28Z

Dan

the floor track about to go into the channel. The pipe is from a propane tank slung too low underneath!

2009-07-20T21:23:39Z

Dan
the floor track about to go into the channel. The pipe is from a propane tank slung too low underneath!

A rear door partly filled with Dow Great Stuff foam.

2009-07-20T21:11:13Z

Dan
A rear door partly filled with Dow Great Stuff foam.

A side wall panel filled and before being sawn flat

2009-07-20T20:59:33Z

Dan
A side wall panel filled and before being sawn flat

Dan's photo

2009-07-20T20:26:52Z

Dan

Dan's photo

2009-07-20T21:10:45Z

Dan

Dan's photo

2009-07-20T20:57:20Z

Dan

Dan's photo

2009-07-21T13:55:29Z

Dan

First pass completed at sawing the door foam flat.

2009-07-21T14:03:56Z

Dan
First pass completed at sawing the door foam flat.

Dan's photo

2009-07-21T15:06:08Z

Dan

Wall foam sawn flat

2009-07-21T12:14:08Z

Dan
Wall foam sawn flat

Dan's photo

2009-07-21T12:34:23Z

Dan

The Stanley 4" corner braces were used to help put up the ceiling tracks.

2009-07-20T21:23:04Z

Dan
The Stanley 4" corner braces were used to help put up the ceiling tracks.

The 2x4 will help stiffen the ceiling L-track and help capture the panels.

2009-07-20T21:07:11Z

Dan
The 2x4 will help stiffen the ceiling L-track and help capture the panels.

A 2x4 sized to fit between ribs

2009-07-20T21:45:33Z

Dan
A 2x4 sized to fit between ribs

Dan's photo

2009-07-20T21:54:25Z

Dan

Future site of my Fantastic Fan.

2009-07-20T21:55:31Z

Dan
Future site of my Fantastic Fan.

Dan's photo

2009-07-20T21:54:17Z

Dan

I used rivet nuts for the back brackets

2009-07-20T21:34:42Z

Dan
I used rivet nuts for the back brackets

Trial sizing of my removable luggage racks. The actual support will be quick release L-brackets.

2009-07-20T20:48:33Z

Dan
Trial sizing of my removable luggage racks. The actual support will be quick release L-brackets.

The aluminum ramp section here is 15" x 75" x 1.5". Only 12 lbs a section.

2009-07-20T20:40:05Z

Dan
The aluminum ramp section here is 15" x 75" x 1.5". Only 12 lbs a section.

A simple ring fitting for the L-track. I'll use threaded bolt fittings for cabinets and seat belts

2009-07-20T22:08:46Z

Dan
A simple ring fitting for the L-track. I'll use threaded bolt fittings for cabinets and seat belts

I used stainless nuts, bolts, lock washers and fender washers for the through-floor track securement.

2009-07-21T12:27:55Z

Dan
I used stainless nuts, bolts, lock washers and fender washers for the through-floor track securement.

Dan's photo

2009-07-21T13:48:01Z

Dan

This shows a quick mockup with 8 pieces of aluminum ramp deployed to give me a sense of the sizing. 5 pieces are shown as shelves. 3 pieces are used for a 45x75 bed. There will be swing ...

2009-07-21T20:45:49Z

Dan
This shows a quick mockup with 8 pieces of aluminum ramp deployed to give me a sense of the sizing. 5 pieces are shown as shelves. 3 pieces are used for a 45x75 bed. There will be swing ...

Dan's photo

2009-07-21T21:27:22Z

Dan

Sure will be nice when the interior panels cover the bare foam.

2009-07-07T15:26:21Z

Dan
Sure will be nice when the interior panels cover the bare foam.

These ramps are upside down as I'm cheating for the mockup by overlapping their flanges with the L track flanges.

2009-07-07T14:53:37Z

Dan
These ramps are upside down as I'm cheating for the mockup by overlapping their flanges with the L track flanges.

Dan's photo

2009-07-21T20:35:08Z

Dan

I've removed one section from the double bed to yield a 30" single

2009-07-21T21:28:25Z

Dan
I've removed one section from the double bed to yield a 30" single

The Supervisor has come to inspect my work. There will be drop-in plywood panels covered with foam and vinyl for seating and backrests. We will sleep on an overlayer of memory foam.

2009-07-21T22:19:19Z

Dan
The Supervisor has come to inspect my work. There will be drop-in plywood panels covered with foam and vinyl for seating and backrests. We will sleep on an overlayer of memory foam.

The Dear Wife approves

2009-07-21T22:10:55Z

Dan
The Dear Wife approves

Dan's photo

2009-07-21T21:29:09Z

Dan

The lower two shelves on the right rearranged to form another twin bed. It'll look better when the legs are built.

2009-07-21T22:16:43Z

Dan
The lower two shelves on the right rearranged to form another twin bed. It'll look better when the legs are built.

Another view of the two twin arrangement. You could add another couple of twins by suspending them from the ceiling and sidewall L-track. Hammocks might be easier.

2009-07-21T21:51:49Z

Dan
Another view of the two twin arrangement. You could add another couple of twins by suspending them from the ceiling and sidewall L-track. Hammocks might be easier.

The ramp sections come with slip hinges

2009-07-21T22:22:03Z

Dan
The ramp sections come with slip hinges

Two shelves stacked

2009-07-21T21:33:12Z

Dan
Two shelves stacked

The hinges are used here to convert a twin bed into a bench when the legs are retracted

2009-07-21T22:19:27Z

Dan
The hinges are used here to convert a twin bed into a bench when the legs are retracted

Another view of the slip hinge

2009-07-21T22:05:14Z

Dan
Another view of the slip hinge

A lot of room with the bed made into a bench

2009-07-21T21:59:35Z

Dan
A lot of room with the bed made into a bench

Even more floor space when the shelves are lashed to the wall.

2009-07-21T22:14:31Z

Dan
Even more floor space when the shelves are lashed to the wall.

Nice and narrow for odd loads. The beds will be able to be free standing. We have a nice cabin wall tent that has more headroom than the Sprinter! I'll have some taller supports for table ...

2009-07-21T22:35:39Z

Dan
Nice and narrow for odd loads. The beds will be able to be free standing. We have a nice cabin wall tent that has more headroom than the Sprinter! I'll have some taller supports for table ...

A cover panel made from a recycled window cutout.

2009-07-22T15:43:51Z

Dan
A cover panel made from a recycled window cutout.

Progress! Here are some of the plywood panels that will fit between the L-track flanges

2009-07-22T15:21:28Z

Dan
Progress! Here are some of the plywood panels that will fit between the L-track flanges

More panels...and the boxes are some of the agm batteries. The ups man is not speaking to me anymore...

2009-07-22T15:32:24Z

Dan
More panels...and the boxes are some of the agm batteries. The ups man is not speaking to me anymore...

Danny reinforcing a window panel

2009-07-22T15:33:33Z

Dan
Danny reinforcing a window panel

A nice Feb day in Boston gets the sawdust outdoors

2009-07-22T15:10:10Z

Dan
A nice Feb day in Boston gets the sawdust outdoors

Ply panels ready for trial fit

2009-07-22T15:14:16Z

Dan
Ply panels ready for trial fit

Wheelwell cutout panel

2009-07-22T16:14:24Z

Dan
Wheelwell cutout panel

Panel heights adjusted. Lengths will be matched.

2009-07-22T14:52:36Z

Dan
Panel heights adjusted. Lengths will be matched.

Dan's photo

2009-07-22T15:49:21Z

Dan

Dan's photo

2009-07-22T15:20:28Z

Dan

The panels end here by the sliding door. The marine vinyl wrap will extend a bit farther.

2009-07-22T15:43:46Z

Dan
The panels end here by the sliding door. The marine vinyl wrap will extend a bit farther.

We're using some scrap see-through vinyl to try to make a window opening template.

2009-07-22T15:21:48Z

Dan
We're using some scrap see-through vinyl to try to make a window opening template.

Just too hard to capture a consistent curve point. Danny ended up cutting a reduced opening instead and scribed the final cutline onto the window plywood.

2009-07-22T15:44:37Z

Dan
Just too hard to capture a consistent curve point. Danny ended up cutting a reduced opening instead and scribed the final cutline onto the window plywood.

I'm using a Japanese saw knife to remove high points from the foam.

2009-07-22T15:41:39Z

Dan
I'm using a Japanese saw knife to remove high points from the foam.

Labor of love. Enough said.

2009-07-22T15:41:49Z

Dan
Labor of love. Enough said.

Dan's photo

2009-07-22T15:17:40Z

Dan

Pretty nice for underlayment. That's foam not snow on the floor!

2009-07-22T15:31:04Z

Dan
Pretty nice for underlayment. That's foam not snow on the floor!

Dan's photo

2009-07-22T14:55:28Z

Dan

The window panel is doubled for strength. They still need to be glued together.

2009-07-22T16:03:09Z

Dan
The window panel is doubled for strength. They still need to be glued together.

The upholstery stapler arrived!

2009-07-22T15:42:11Z

Dan
The upholstery stapler arrived!

A sandwich of 1/4" ply, 3/8" closed cell foam and marine vinyl.

2009-07-22T15:56:47Z

Dan
A sandwich of 1/4" ply, 3/8" closed cell foam and marine vinyl.

Dan's photo

2009-07-22T15:34:41Z

Dan

Hawaiian Blue looks good on Ground Hog Day...

2009-07-22T15:19:51Z

Dan
Hawaiian Blue looks good on Ground Hog Day...

Vinyl sandwiches are nice but who could resist a nice bowl of Rivet Nuts?

2009-07-22T15:24:43Z

Dan
Vinyl sandwiches are nice but who could resist a nice bowl of Rivet Nuts?

7500 btu Espar Airtronic D2 about 4.5"x4.5"x13" located about 4 ft behind the drivers seat

2009-07-07T18:13:44Z

Dan
7500 btu Espar Airtronic D2 about 4.5"x4.5"x13" located about 4 ft behind the drivers seat

Mini-controller thermostat to mount on the wall. More elaborate programmable timers also available.

2009-07-22T16:54:20Z

Dan
Mini-controller thermostat to mount on the wall. More elaborate programmable timers also available.

I had mercy on the installer and held off on boxing in this and the electricals that will go nearby.

2009-07-07T18:00:38Z

Dan
I had mercy on the installer and held off on boxing in this and the electricals that will go nearby.

The hot air end

2009-07-22T16:29:20Z

Dan
The hot air end

The tailpipe ahead of therear wheel. The Espar manual shows an optional muffler but I could barely hear this!

2009-07-07T18:38:30Z

Dan
The tailpipe ahead of therear wheel. The Espar manual shows an optional muffler but I could barely hear this!

There is a floor gasket below the unit. The silver pipe is the diesel exhaust, the fat black pipe the air intake, the clear hose the diesel feed, the thinner black wire the fuel pump contro ...

2009-07-07T17:51:39Z

Dan
There is a floor gasket below the unit. The silver pipe is the diesel exhaust, the fat black pipe the air intake, the clear hose the diesel feed, the thinner black wire the fuel pump contro ...

A poor picture showing the diesel tank tap. It is the black hose on the right with the metal fitting that stops far enough above the tank bottom to leave some driving reserve.

2009-07-07T18:27:40Z

Dan
A poor picture showing the diesel tank tap. It is the black hose on the right with the metal fitting that stops far enough above the tank bottom to leave some driving reserve.

This is the gasketed, vented propane locker from Adrian

2009-07-23T08:00:44Z

Dan
This is the gasketed, vented propane locker from Adrian

It holds 20, 30 or 40 lb propane bottles. I'll have a shelf at the top for fittings and accessories

2009-07-23T07:24:13Z

Dan
It holds 20, 30 or 40 lb propane bottles. I'll have a shelf at the top for fittings and accessories

My electrical panel with main ac, ac subpanel and a dc subpanel

2009-07-23T07:57:30Z

Dan
My electrical panel with main ac, ac subpanel and a dc subpanel

Dan's photo

2009-07-23T08:32:31Z

Dan

Dan's photo

2009-07-20T13:11:19Z

Dan

I started to put rivnut fittings into the ramp bottoms for a standard attachment point

2009-07-23T07:54:44Z

Dan
I started to put rivnut fittings into the ramp bottoms for a standard attachment point

Dan's photo

2009-07-23T07:28:17Z

Dan

I hear the 2007 Sprinter will be 6" taller!

2009-02-21T11:25:56Z

Dan
I hear the 2007 Sprinter will be 6" taller!

Who needs a light saber when you can have a Japanese saw?

2009-02-21T11:15:22Z

Dan
Who needs a light saber when you can have a Japanese saw?

This sandwich is a trial of ramp, cushion, sheet, memory foam

2009-02-21T11:26:47Z

Dan
This sandwich is a trial of ramp, cushion, sheet, memory foam

The sheet/memory foam bundle is pretty light

2009-02-21T11:21:51Z

Dan
The sheet/memory foam bundle is pretty light