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  1. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 13 (above) At 14", the driver side cabinet felt just a bit too deep, so I cut it down to 12"... (above) It was easier to cut than I anticipated...Festool rail saw and a handsaw got it done... (above) In the shop both cabinets get fine tuned... (above) Drawer guide backing strips are...
  2. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 12 (above) Today, the rear cabinets come together...Using 1/2" ACX fir plywood, the basic parts are oversize cut by 3/4" and propped in place... (above) Almost all the parts will be scribed to fit...For now, oversize is fine... (above) Driver side cabinet, scribed, cut, fitted, scribed...
  3. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 11 (above) With the rear doors done, the walls of the rear cabin get filled with fiberglass insulation... (above) Curb side... (above) Over the insulation, 1/4" plywood is screwed to the metal walls...After each panel is placed, a quick electrical check is done to be sure no hidden wires...
  4. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 10 (above) Fiberglass Reinforced Plastic (FRP) are the panels for the doors...The top panel is attached with two adhesives...Silicone caulking around the perimeter, and contact cement for the middle...The silicone is the primary adhesive, and the contact cement locks it in place while the...
  5. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 10 (above) The L-Track discs give you some serious supplemental tie-down options...Options are good... My ride...drop down table...See it...???... (above) It is the second most favorite built-on that people like about my van...I'm putting one on each rear door of Alex's Sprinter...
  6. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 10 (above) The plastic seat belt concealer on the curb side had a big crack... (above) On the outside (not seen here) I masking taped the break together...Flipped over, fiberglass cloth is laid over the split... (above) Brushed on some epoxy resin... (above) After the epoxy hardens...
  7. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    Q & A... O.H.... Thanks (as always) for the kind words...Your stoke helps to keep the fire burning hot... M.H....For the 140", I think three boxes might be enough, four for sure...Leftovers would certainly get eaten up in some other dish... J.A. (AKA: Alex)...No worries, my mojo is dialed...
  8. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 9 (above) The ceiling foam insulation still needed to get finished...Again the spray contact cement cannister and gun made life easier...I did zero masking off of the sheet metal inside, it's that accurate... (above) This turned out great, considering that with contact cement, you get one...
  9. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 9 (above) Alex sent two boxes of Roadkill for the floor, and maybe the doors... (above) Everything should be this easy to install...Peel and stick...Just be careful not to step on the peeled off paper...Like Teflon on ice... (above) Besides a knife, a hard rubber roller and a soft rubber...
  10. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 8 (above) With the roof work done, it's back to the inside...I put some L-Track discs up high...They are bolted through, (not just sheet metal screwed) through the high crossbars...This one is over the rear doors...The high rear stop light is removed to get the bolts tightened... (above)...
  11. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 8 (above) The forecast was less than 50 / 50, so the roof work got finished...The E-Track discs need uncommon bolts...I ground off some tips of the self tappers to get them to work with standard nuts... (above) Any day you get to make sparks is a good day... (above) Under the tarp is...
  12. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 6 (above) After finishing the under-seat work, it's time to pre-wire the rear cabin...First up, install a shore power inlet...It might be handy if you are camped out with access to 110 volt AC...Maybe for a heater or a microwave or something power hungry like that... (above) Installed...
  13. PaulJensen

    EarthRoamer XV-JP "Northwest Edition"

    Excuse me for the diversion... Some of you might be interested in the current build I'm working on...It's a Sprinter conversion...Custom all the way...I'm just getting started... Sprinter Conversion for Alex
  14. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 6 (above) Now, with most of the work focused in the rear cabin, I pulled out the scrap carpet I use in my van sometimes...It'll be easier on the hands and knees when I'm doing things back there...It's just temporary... (above) Despite the record run of perfect weather, it's September and...
  15. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    I will not be using the corrugated plastic panels...I dislike them on so many levels...Even as patterns for new panels they aren't so great...I'm better off making my own patterns, it's not that hard...For this build I'll likely (still undecided) to use 1/8" luan ply, covered with something...
  16. PaulJensen

    Anyone using roofrack mounted water storage?

    (above) What we have here is 4" PVC water pipe, epoxied at the seams and mounted using a combo of SS hose clamps (with washers and bolts through the side wall) and HD Zip-Ties looped through the factory cut outs on the wall...The red plug at the top is where it fills...I use a one gallon jug to...
  17. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 6 (above) The table will be accessible from either the front seat once it's pivoted, or from a chair (or ice chest)...With the table dropped down, the ice chest can also serve as a jump seat...I'm liking this design...Another grey panel was taped in place, then the rest of the cabinet plan...
  18. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 5 (above) These bolts need to be firmly mounted, no doubt...I started with a lock washer and a standard nut...I tightened it with an impact driver... (above) The installation is done here...If you look close you can see that on top of the standard nut is a nylon locking nut, again driven...
  19. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 4 (above) After the pant set up, it's time to get started on the fun stuff... (above) The seats were as dirty as something from an Oklahoma junkyard...Our weather forecast is warm and dry for a few days so the twins got a soaking and scrubbing...Gawd, they were filthy...Now there are only...
  20. PaulJensen

    2005 118" Sprinter Conversion for Alexander

    # 3 (above) With a stretch of warm dry weather forecast, it's a good time to cut in and install the roof vent...The 14" cut out square was penned onto the roof and cut out with a worm drive saw with a dry diamond blade...Sparky... (above) The hole edges needed filing... (above) The roof...
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