nyyankees588
Active member
Are you planning for the plywood/epoxy boxes to be DIY roof boxes? I've toyed with that exact idea.... but never actually made it happen. Would be interested to see how it turns out if that's what you're thinking.
E350 10ft Box Van
- Thread starter Burlydirtyhippy
- Start date
Burlydirtyhippy
Chambon
Oaxaca
Burlydirtyhippy
Chambon
DIY roof boxes, yes...
I keep going back and forth with what I am going to do,,, originally idea was XPS foam, glass and epoxy for a complete box,,, then was thinking 1/4” ply, glass and epoxy,,,, now maybe just marine ply, epoxy and aluminum skeleton, the top of the box would essentially be the solar panels, the ply would just be for the side risers and the existing rack would be the bottom..... I am headed into town today for supplies and still am not sure which way I am going to go,,,lol.
Bikersmurf
Expedition Leader
Having plywood in the buildup would be beneficial, especially at attachment points. I’d likely use T-nuts for mounting points where possible. Foam would be good for weight savings, however it wouldn’t be as beneficial at mounting points.
nyyankees588
Active member
Cool - I look forward to what you come up with. The XPS foam route would be awesome for how light it'd be...
Burlydirtyhippy
Chambon
Added a table with Lagun leg. Wife is making new cushion covers.
Burlydirtyhippy
Chambon
Marine ply, epoxy, aluminum channel and a few cans of spray paint. Need to clean up the solar wiring, and make two doors for the rear of the boxes. We are 10’5” overhead clearance. By lifting the panels and adding the boxes we were able to gain a roof fan, another solar panel, room for two more boards and be easily locked and not have to crawl all over the roof to strap them down. We gained less than 3” of overall clearance and a lot of functionality....
nyyankees588
Active member
Sweet - came out good. It looks like the panels don't cover the entirety of the box so the interior isn't water-tight? What do you plan on storing inside of them? Or maybe I'm looking at it wrong and the boards fit inside of the boxes?
Burlydirtyhippy
Chambon
Thanks! They are not water tight, two surfboards in bags on each side. We will be able to slide them in from the rear and lock the doors, will be a lot easier than crawling over the roof to strap them down and much more secure.
nyyankees588
Active member
Gotcha - that's sweet. How do the aluminum channel pieces come together? Are they welded at the corners or just attached to the wood and meet at the seems?
Burlydirtyhippy
Chambon
They meet at the seams and are sealed/attached with 3m Marine Adhesive.
Coachgeo
Explorer
hmmm..... Your probably planning for this already............... but if not.... IMHO brush of tree limbs are going to rip out your solar wires.... consider go under the panels..... under each box. inside fixed tube or ?? over to the wire port . Maybe put the wire port under one of the boxes while your at it??
Burlydirtyhippy
Chambon
Yes, I agree. I have them hooked up temporarily, I need to lengthen and run them in a more protected manner.
Pacific Northwest yetti
Expedition Medic
Great joob!
Awesome well thought out, and practical build out.
Thanks for posting
Awesome well thought out, and practical build out.
Thanks for posting
Burlydirtyhippy
Chambon
Dang. Almost like clockwork was pulling 10.4mpg. Now with the boxes 9.7mpg. Currently headed south.......
