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As I said before, I would stay away from the L or T shaped profiles unless you significantly increase their size. I ran the T-profile you showed above, and it would fail. I increase the T-profile dimensions to 3" x 3" x .25"thick (76mm x 76mm x 6mm thick) . My load was ~200kg, evenly distributed...

I owned an AWD version for 10 years. Coming from a Subaru, i can say the Honda AWD system sucked. It only kicked in if a wheel started spinning. That might be fine on dirt roads, but on ice, it just meant you would go from one wheel spinning to four wheels spinning. Max payloads was 800lb. I...

If you need to calculate the moment of inertia for different shapes, this calculator seems to work well: https://calcresource.com/moment-of-inertia.html

I think you should stick with square or rectangular tubing. The rigidity of the material is a function of the surface area of the profile, and the distance from the center of the profile. The L-shaped material is only two walls, where a square profile is 4 walls, probably twice the material. The...

I have a similar build going and I posted how to calculate deflection in the build thread: Expedition Portal Compact Van forum. I think it shows all of the information you will need to collect and also has an online beam calculator linked. Just looking at your design, I think you definitely...

This build is terrific. Thanks for all the info. Do you have a link for the donor ladder on these steps?

Beam Calculation I’ve been busy and still need to finish a few things on the soft top. The door needs to be sewn, and a bit of material added to the door area to get it to hang straight. Since I didn’t have time to sew, I started sizing some elements of the camper design. My camper design...

That's a sweet rig. LHD is great for anyone wanting to do some travel in South America. I hope someone buys it to do some travel. Thanks for the info on turbo/engine reliability. Reliability will be very important to me, so maybe there isn't a turbo in my future. Slow is fine.

I did some sewing over the last week or two. As I said, I have a background in CAD, so I designed the frame and fabric before I got started. After having a couple of large tents, I also know improvisation is required. Fabric moves and CAD doesn't. Each piece is laid out and cut. I wanted to...

Thanks for the reply. These are fun little trucks. Do you have any pictures of your Hiace? It is the 2L, which is 2,446 cc, I guess that is 2.4L, sorry about the rounding error. No turbo, sadly. I'm researching some kits from Australia that add the 2LT intake and a small turbo to the 2L engine...

I see. Thanks for that. I'm aware that trail thefts occur and that a fabric cover isn't a deterrent. I'm not planning to leave anything in the truck unattended/unsecured. The softcover is to keep things dry while I'm around. No long-term travel will happen with this truck until a camper is added.

Got some work done on the frame. I'm using 3/4 emt. This is a temporary solution until I get a camper designed and built, so the poles don't need to be heavy duty or last 30 years. I hacked the brackets out of mild steel plate and angle using an angle grinder. I could have been more methodical...

Do you care to elaborate?

I recently purchased one of these strange trucks from Vanlife NW in Portland, OR. They add a lift kit, put 30" KO2's on, replaced a bunch of seals, hoses, and replaced the fluids. You have probably seen these before. They are different from Hiace vans, which are unibody. These have a...