Sprinter

02 Freightliner Sprinter 2500 long, tall with full roof rack

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:23:42 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:41:07 -0800

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:37:25 -0800

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:32:50 -0800

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:24:03 -0800

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:24:29 -0800

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

Previous owner had only an outlet for electricity.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:27:09 -0800

Dan
Previous owner had only an outlet for electricity.

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:25:27 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:25:50 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:26:14 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:26:37 -0800

Dan

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:25:01 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:27:43 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:28:21 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:28:51 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:29:21 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:34:05 -0800

Dan

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:29:52 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:30:20 -0800

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

A side wall panel filled and before being sawn flat

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:30:43 -0800

Dan
A side wall panel filled and before being sawn flat

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:31:07 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:31:29 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:31:52 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:08:51 -0800

Dan

First pass completed at sawing the door foam flat.

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:09:26 -0800

Dan
First pass completed at sawing the door foam flat.

Dan's photo

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:09:49 -0800

Dan

Wall foam sawn flat

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:11:39 -0800

Dan
Wall foam sawn flat

Dan's photo

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:12:03 -0800

Dan

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:33:20 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:34:35 -0800

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

A 2x4 sized to fit between ribs

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:35:22 -0800

Dan
A 2x4 sized to fit between ribs

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:35:46 -0800

Dan

Future site of my Fantastic Fan.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:37:02 -0800

Dan
Future site of my Fantastic Fan.

Dan's photo

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:37:47 -0800

Dan

I used rivet nuts for the back brackets

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:38:20 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:39:03 -0800

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.

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:39:28 -0800

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

nobody@smugmug.com (Dan) — Tue, 20 Dec 2005 10:40:17 -0800

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.

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:10:43 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Thu, 05 Jan 2006 07:11:13 -0800

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 ...

nobody@smugmug.com (Dan) — Fri, 13 Jan 2006 20:21:59 -0800

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

nobody@smugmug.com (Dan) — Fri, 13 Jan 2006 20:22:53 -0800

Dan

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

nobody@smugmug.com (Dan) — Fri, 13 Jan 2006 20:23:24 -0800

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.

nobody@smugmug.com (Dan) — Fri, 13 Jan 2006 20:23:48 -0800

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

nobody@smugmug.com (Dan) — Fri, 13 Jan 2006 20:24:12 -0800

Dan

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 19:57:16 -0800

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.

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 19:57:38 -0800

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 19:58:14 -0800

Dan
The Dear Wife approves

Dan's photo

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 19:58:37 -0800

Dan

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 19:59:07 -0800

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.

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 19:59:38 -0800

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:00:05 -0800

Dan
The ramp sections come with slip hinges

Two shelves stacked

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:00:28 -0800

Dan
Two shelves stacked

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:00:52 -0800

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:01:17 -0800

Dan
Another view of the slip hinge

A lot of room with the bed made into a bench

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:01:44 -0800

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

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

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:02:09 -0800

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 ...

nobody@smugmug.com (Dan) — Sat, 14 Jan 2006 20:02:36 -0800

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.

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:22:31 -0800

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:19:22 -0800

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...

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:19:49 -0800

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:26:52 -0800

Dan
Danny reinforcing a window panel

A nice Feb day in Boston gets the sawdust outdoors

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:20:12 -0800

Dan
A nice Feb day in Boston gets the sawdust outdoors

Ply panels ready for trial fit

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:21:02 -0800

Dan
Ply panels ready for trial fit

Wheelwell cutout panel

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:22:56 -0800

Dan
Wheelwell cutout panel

Panel heights adjusted. Lengths will be matched.

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:21:24 -0800

Dan
Panel heights adjusted. Lengths will be matched.

Dan's photo

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:20:33 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:25:14 -0800

Dan

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:21:49 -0800

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.

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:23:17 -0800

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.

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:23:39 -0800

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.

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:24:52 -0800

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

Labor of love. Enough said.

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:25:36 -0800

Dan
Labor of love. Enough said.

Dan's photo

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:26:03 -0800

Dan

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:28:29 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:28:54 -0800

Dan

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:29:32 -0800

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

The upholstery stapler arrived!

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:30:21 -0800

Dan
The upholstery stapler arrived!

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:28:04 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:27:36 -0800

Dan

Hawaiian Blue looks good on Ground Hog Day...

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:27:14 -0800

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

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

nobody@smugmug.com (Dan) — Thu, 02 Feb 2006 18:22:10 -0800

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

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:01:48 -0800

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.

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:02:08 -0800

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.

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:02:36 -0800

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

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:03:06 -0800

Dan
The hot air end

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

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:03:27 -0800

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 ...

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:03:52 -0800

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.

nobody@smugmug.com (Dan) — Sun, 05 Feb 2006 13:04:14 -0800

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

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:31:16 -0800

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

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:31:40 -0800

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

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:32:07 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:32:28 -0800

Dan

Dan's photo

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:32:53 -0800

Dan

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

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:33:14 -0800

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

Dan's photo

nobody@smugmug.com (Dan) — Sat, 25 Feb 2006 06:33:35 -0800

Dan

I hear the 2007 Sprinter will be 6" taller!

nobody@smugmug.com (Dan) — Mon, 27 Feb 2006 07:20:48 -0800

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

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

nobody@smugmug.com (Dan) — Mon, 27 Feb 2006 07:21:13 -0800

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

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

nobody@smugmug.com (Dan) — Mon, 27 Feb 2006 07:21:40 -0800

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

The sheet/memory foam bundle is pretty light

nobody@smugmug.com (Dan) — Mon, 27 Feb 2006 07:22:03 -0800

Dan
The sheet/memory foam bundle is pretty light