Hodakaguy's 4x4 Sprinter Build

Betarocker

Adventurer
On to roof racks......

I knew from the beginning that we wanted a roof rack included in the build, they are great for hanging out on and enjoying the birds eye view. On our Unimog build my father and I built our own rack and we thought about doing the same for the van....but in the interest of time I decided to purchase a rack instead. I originally settled on the RoamBuilt rack as I love the look of their rack on the van and the round lights on the front vs a LED light bar. I spoke with Roambuilt several times at overland events over the summer and they were very friendly. I finally decided it was time to pull the trigger and get one on order....well, that was the plan anyways. I went to RoamBuilt's website to contact them about some questions on light mounting and lead time, they list no phone number so your forced to contact them through email. I sent off an email and got a reply that the lead time was 8 weeks and I responded that I'd like to get one on order. I asked for a phone number but they wouldn't provide one which was frustrating as I had several questions about mounting Baja Designs lights to their rack which is different than the units they usually use, solar mounting options etc and a quick call would cover a lot of ground. Their reply to emails is sporadic at best, at times it would take numerous days to get a reply back via email and even if I sent a reply back within minutes of receiving an email it would take days again to get the next reply. I did a quick google search and customer service and accurate lead times seemed like something they don't have a great reputation for. Soon 2 weeks had already passed while I was still trying to get my questions asked....time to start looking at other options as summer is approaching. (Side note if you want to go with RoamBuilt I would suggest going through one of their dealers that you can actually call instead of trying to deal with RoamBuilt directly).

As I was looking for other rack options I came across a company called Stoked Adventure Outfitters in Canada that make some great looking racks as well. They make several different style aluminum racks and they are within driving distance for me, bonus! I contacted Stoked via email and got an instant reply back, questions were answered in almost real time! Stoked also provides a phone number and was more than willing to answer any questions that I had. They will customize the rack to fit what ever lighting you choose to go with and provide solar panel mounting for the panels of your choice. I liked that Stoked uses thicker 3/16" aluminum punch plate on the deck which makes it rock solid, we will have chairs up there etc so stability is important. Stoked said the lead time is 5 weeks and that time frame is accurate. I pulled the trigger and the rack was on order! Stoked kept me updated and even sent me pics during the build process...nice!

Fast forward to the Covid-19 outbreak and Stoked was working hard to finish the rack ahead of schedule before the shop providing their powder coating shut down. They finished the rack early and send me a message that it was ready to be picked up. Originally we were going to make a family weekend trip up to Canada to pick up the rack but with the Covid lock down in place we decided that shipping might be the better option. Stoked did an awesome job crating the rack and arranging shipping to WA, 3 days later the rack was delivered and in hand!

The rack in the crate as it arrived...Nice job on the crating!

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Great attention to detail to ensure the powder coating remained undamaged.

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Lot's of bracing under the punch plate, will make for a nice solid deck.

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And out of the crate. No shipping damage....Sweet!

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The solar panel will mount into the provided aluminum bracing on on the upper portion of the front rack and cover the open section where the punch plate stops. (Red Arrows)

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These are the aluminum backing plates that slide into the factory roof rails and tie the mounting feet down to the roof rails.

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Got busy and didn't snap pics of the install...but it looks great! Can't wait to get the lights and solar panel installed, it will fill out the front portion of the rack nicely. The rack will sport 6 Baja Designs LP-9 lights facing forward and 6 flood lights (2 on each side and 2 on the rear). The rack will also sport a 10' Fiamma awning on the passenger side and a single Renogy Mono Solar Panel.

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The upper deck. The deck is very solid and will make a great platform to hang out on, just be careful as its a LONG ways down from the top!

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Very happy with the Stoked rack, quality is great and their customer service is top notch! If your in the market for a Sprinter or Transit rack I'd highly recommend Stoked Adventure Outfitters.


Hodakaguy

I just found out a good friend of mine owns Roambuilt. He recently moved back to the Vancouver, BC area and is running the business remotely until travel restrictions ease. His wife's new job prompted the move.
 

Hodakaguy

Adventurer
I just found out a good friend of mine owns Roambuilt. He recently moved back to the Vancouver, BC area and is running the business remotely until travel restrictions ease. His wife's new job prompted the move.

They make great stuff, hopefully their customer service will improve with the change. I haven't talked to a single person at shows that's had anything good to say about their customer service.

Hodakaguy
 

Hodakaguy

Adventurer
Parts are starting to show up, lot's of mods coming soon!

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While I'm waiting for the new suspension to show up i decided I would make some progress and get the new tire carrier installed.

I wish all products came packaged with the care and detail that the OWL setup showed up with. You can really tell they care about their product and want to make sure that the end user has the best experience possible.

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Popping off the door panels. I like to use an extended reach clip removal tool, I reach down into the door and pop each clip by applying pressure as close to the clip as possible. This allows me to easily remove the panel without worry about breaking clips.

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Installing the bolts through the hinges. The bottom bolt (Stainless) has been ground down to fit the slightly smaller recess and prevent the door from binding. Everything is kept slightly loose at this point.

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Washers are used to shim up the hinges. Didn't get a photo but there are plastic bushings that insert into the carrier where the bolt slides through.

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The OEM magnet is removed off the rear door and an internal reinforcement plate is installed. Then the insulation and door panel are re-installed.

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All bolts are tightened up at this point. Grease was installed on the bolts/pivot points.

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Nice and solid! Quality of the whole setup is top notch! Now the wait for suspension and getting the new tires installed on the wheels so I can mount the spare on the rack.

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Lot's more to come.....

Hodakaguy
 

ITTOG

Well-known member
Looks like it was a good trip. I am sure your father is loving the time spent together.

Glad to see you back. It has been a long time. I thought maybe you got a new hobby!
 

Hodakaguy

Adventurer
Looks like it was a good trip. I am sure your father is loving the time spent together.

Glad to see you back. It has been a long time. I thought maybe you got a new hobby!

Nope still loving the van, but it's been a while since I've been working on it. Back in the game now! :)

Hodakaguy
 

Hodakaguy

Adventurer
Range Baby!!

A longer range fuel tank has been on our wish list for a while now. We love to travel to remote areas, and not having to worry about fuel is a Huge benefit when traveling away from civilization. The larger fuel tank also allows us to skip areas that are high priced and fuel up where prices are lower.

We ordered the tank from Cory at Peak10Customs and had the tank in just over a week. The tank came well packaged, and nothing was damaged. The install instructions are online, and a QR code is included with the tank to access them. There is also a YouTube video showing the install that covers it pretty well...for the most part.

New tank came well packaged and in great cond.

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OEM Tank before Removal.

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Separating the Fuel lines. Here I used some Little Red Caps (Normally used to cover the open tips on Caulking tubes) to slide over the open fuel lines to prevent any dirt intrusion....and yes I know what they look like lol. These have been super handy for many uses around the shop.

Note: The links below are my Amazon Affiliate links, I make a small portion each time someone purchases from Amazon using one of my links, at no extra cost to the buyer. I only provide links to items that I personally like and use myself. i use the money to put back into my builds and support making videos/posts. If you prefer not to use my links you can search for the same items directly off Amazon. Thank you for the support!

Amazon link to the generic version of these here (Same thing and more cost effective): CLICK HERE

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Removing the stock tank. After disconnecting the fuel lines and electrical connector, removing the fuel filler tubing retaining bolts and tank retaining straps it's time to remove the OEM tank. Here I used a jack to drop the tank down and slide it out from under the van.

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A Ziplok bag keeps the female ends clean on the fuel lines.

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Just a bit of difference between old and new! This is the tank the van should have left the factory with!

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Here's the OEM Fuel sender assembly that will be removed and transferred to the new tank. Make sure you clean all the dirt off and around this assembly before removal as you want to keep the internal parts as clean as possible.

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They make a special tool to remove the threaded hold down ring that you can pick up at the auto parts store, that said I had a large pair of channel locks that worked perfectly.

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New O-ring installed on the S&B tank, ready for the fuel pick up assembly to be installed.

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I had ran the fuel tank down quite a ways but there was still some residual fuel left. I transferred 5.2 gallons into a fuel can and will use this to pour into the new tank once it's installed, this will allow me to drive down to the fuel station for a full fill up.

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Continued Below.....
 

Hodakaguy

Adventurer
Continued from above.....

Performing the pressure test. With the fuel pick up assembly installed in the new tank we covered the ports and used some low air pressure to test for leaks around the O-ring seal, all good! The instructions from S&B said that the tank comes with a rubber cap to put over the filler port then you poke a hole in the cap and put the air in at that point. Our kit was missing the rubber test cap but a stack of paper towels with a hole poked in the middle worked just fine.

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The upper vent hose assembly gets cut off the original tank and will be re-used on the new tank.

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Here the filler neck assembly has been cut off the OEM tank and is about to be installed on the new tank. There is an internal check valve that gets installed in the included rubber filler neck hose (Only snapped a picture once it was already installed in the hose).

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Ready to go back in the van. The filler neck hose clamps are left slightly loose at this point so you can rotate the filler piping up into place as you slide the tank under the van, once in place then they can be tightened up. The instructions showed installing 3 clamps total on the filler neck but my kit was only supplied with two clamps, I had another spare on hand so it wasn't a big deal.

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Getting ready to re-install.

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Tank installed in place and filler neck tightened back up, guards haven't been re-installed yet in this picture.

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On the rear of the tank there is a vent line that is slid through the boxed section of the frame then connected to another vent barb on the forward section of the tank during install. The instructions show just sliding the hose through the OEM holes and letting it rest on the metal. I was concerned about wear on the hose over time so installed a couple rubber grommets to keep the hose from resting on the metal.

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On the OEM tank I had my Espar fuel pump mounted on the front metal tank guard. Now that the new tank is installed I had to come up with a new way to mount the pump. I bent up a piece of steel to form a mount that would attach to one of the tank strap mounting bolts, I installed a longer bolt into this location. i didn't spend a ton of time on this making it pretty since it will be living under the van.

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Continued Below.....
 

Hodakaguy

Adventurer
Continued from Above.....

Not a lot of difference in ground clearance, maybe about an inch lower than OEM.

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And installed! The install process took about 3 hrs and was pretty easy over all. One of my tank straps was bent a little long from the factory (The 2nd strap from the front) and isn't quite touching the tank on the drivers side. S&B seen my post on FB and reached out to me saying that had just made a production change and that strap got messed up, they are sending me a correct replacement strap....Nice! I love companies that have great customer service and care about a quality product.

Overall the tank is rock solid and very high quality. It feels tougher than the OEM tank for sure. So glad to have the new tank installed, no more range anxiety! :)

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Hodakaguy
 

Hodakaguy

Adventurer
Teaser pics......New tires mounted up! Oh Yeah!!

The smell of fresh rubber! Going from 235/85-16 up to 285/75/17. This will give us a bit more ground clearance and traction for our off-road adventures.........plus I just love the looks of this combo and let's be honest; that's always a huge factor!
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Just a wee bit of difference.

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And the spare mounted up on the OWL carrier, Looks sooooo good next to the Roam ladder.

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Lot's more to come......

Hodakaguy
 

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