Good progress! I am done with the lower portion, and I put up the upper portion panels for now, just to make sure everything fit. Start to end was about 10 hours of work.
I am glad I picked up a drill press, it would have been impossible without one. After debating and reading some reviews, I picked up a Craftsman 10" drill press for ~$100 locally. If you read Garage Journal (I do) they will tell you to never buy one of these drill presses. Whatever, I got one, and it worked very very nicely for this project. I ended up following my plan of using 3" x 1/8" 6061 Aluminum and used the same self tapping screws that came on the van to attach my brackets. Then I attached the seat brackets by drilling and tapping holes and using 6x1.0mm SS hex head bolts. I was very meticulous about where the aluminum would be secured to ensure no flexing. The front pair differed from the rear only slightly. Here is what the fronts looked like:
At that point I tested the benches for strength and operation then removed them. One might be inclined to ask if I thought 1/8" of threads (x3 bolts) is enough to hold each bracket. I don't know for sure, but it's stout as hell. If I ever have a problem with those bolts I will simply re-do them with a nutsert. For now, they seem great. The only worry really is the bracket bending away from the van wall, and with the position and number of screws I have in there there was zero flex (there is also one right next to the bracket and one down below you can't see in the picture.
Now came the tricky part, or at least I thought. I needed to translate the *exact* position on the bracket to the panel. I needed that position to be on the inside of the panel so I could drill from the back to forward. After a bit of head scratching and brainstorming with my wife, I simply re-threaded the bolts back into the bracket, then used a paint pen to paint the bolt heads, then put the panel up pushing it against the paint. This left 3 perfectly aligned paint marks on the back side of the panel. Then I wiped the paint clean. Bingo:
From there it was as simple as bolting up the bench brackets, and self tapping the wall panels in.
Here are some pics:
I will be putting l-track on the seam horizontally between the two panels, so that line will 'disappear', and another line of l-track at the 45" mark for the upper bed.
I am really happy with the results. The RBComponents stuff is really nicely made. There where a couple of fitment issues, but very very minor, like 1/16" off kind of thing. I racked it up to subtle differences in vans.
