Hodakaguy's 4x4 Sprinter Build

[Hodakaguy]

Continued from above....

Starting to re-install some of the plastic bits. Here I'm getting ready to re-install the passenger side step assy. Couple pieces of sound damper installed.

Installing some Thinsulate in the wells

Next I needed to plug the holes where the roof top AC lines passed though the floor. There are foam plugs in the floor that has holes knocked out for the AC lines, I stuffed in a couple pieces of scrap foam bits a little below flush and sealed it off with some Sikaflex 221.

The foam floor piece with the AC line holes

Scrap foam bits inserted in the holes a little below flush...

And all sealed off with some Sikaflex 221

And plastic re-installed.

Next up time to install the custom 3 way switch assemblies into the ceiling.

And time to install the lighting as well. I'll be using thin touch activated marine LED lighting. You can touch each one to turn on/off and hold to dim.

Mounting the lights onto the ceiling panels. Wires go through the ceiling and two mounting screws hold the assembly in place.

And installed. Lots of light and options with the 3 way switches. Panels are just loosely sitting in the L-track here.

Lookin Good!

Lots more to come.....

Hodakaguy

 

[Arjan]

What a difference that makes !!!!

Looking very, very good - love those touch lights.

What a build !

 

[Hodakaguy]

Not a lot of progress today as I was working on other stuff most of the day. I did install an adjustable LED map/spot light over my son's seating position so he can have light at night without disturbing us up front.

Here's a pic of the light. It has it's own on/off switch and you can point the light where its needed.

Let's see....yep I think right about here will do!

With the location marked on the panel it's time to pull the panel down and cut the hole for the light.

First up I used some calipers to figure out the side of hole needed for the round portion of the light.

Then used the calipers to find something the same size that could be used as a pattern.....hmmm, a set of seal drivers should do nicely

Next back to the calipers to measure overall length needed and mark the cutout location for the switch.

Now a razor blade is used to carefully cut the fabric and foam backing.

I used a solder gun to burn the edges of the fabric to keep it from fraying.

And a jig saw to cut out the wood area.

And installed. This should work great for the kiddo

And finally pulling down the panels in preparation for insulation and electrical work.

More to come...

Hodakaguy

 

[Arjan]

"Not a lot of progress today ....." you said.

These little thingies to do take the most time.

However, they really make or brake a project like this as you see it every time.

Very well done !

 

[Hodakaguy]

"Not a lot of progress today ....." you said.

These little thingies to do take the most time.

However, they really make or brake a project like this as you see it every time.

Very well done !

Thanks Mate, the detail items do eat up a lot of time but like you said they really make the difference in the end!

Hodakaguy

 

[Hodakaguy]

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!

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

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

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

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)

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

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.

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!

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

 

[coguzzi]

what is the weight on the rack if you had to guess

 

[Hodakaguy]

what is the weight on the rack if you had to guess

Stokes lists the weight at 125 lbs bare without lights or solar. I'd say that's pretty accurate as two people can lift the rack pretty easily.

Hodakaguy

 

[Arjan]

Very nice visually - it really works with the rear ladder !

60 Kgs. on the roof is not a lot - but you'll notice it when you start loading it up..

Here in France they have a special roofrack for big ladders to store from the side all the way up there and you can see them roll quite a bit at the roundabouds....

 

[Hodakaguy]

Very nice visually - it really works with the rear ladder !

60 Kgs. on the roof is not a lot - but you'll notice it when you start loading it up..

Here in France they have a special roofrack for big ladders to store from the side all the way up there and you can see them roll quite a bit at the roundabouds....

I wont be carrying much at all up top, I really want it for the platform to hang out on when parked

Hodakaguy

 

[MCX]

The rack looks great!

 

[Hodakaguy]

Lights Baby!

Up this am to lay out the spacing for the front lights. A little measuring and marking...then check everything twice before drilling.

Trying to catch as many of the aluminum shavings as possible

Starting to bolt the lights in place to check for proper spacing. I'll pull them back off again to drill the other two holes on each light.

Here I'm using a scrap piece of metal to make a jig to mark center on the two smaller holes on either side of the main mounting bolt.

To use the jig you put the mounting bolt through the hole in the rack and use a pencil in the small hole to mark the center ark on the side holes.

Then a piece of 1" stock used to mark center

And mounted up. Lots of built in cooling

Test fitting the solar panel, just sitting loosely in this pic. I had this panel already when they made the rack, I may eventually modify the mounts to add a larger panel if the need arises. I will make some trim pieces to fill in the side gaps.

Lights mounted.....going to be bright!!

Hodakaguy

 

[jgaz]

Your little tutorial on the drill jig is the reason I always subscribe to your projects. A person can always learn something from almost anyone.

Did you ever do anything more with the idea of a home built aircraft?

 

[Arjan]

Nice.

 

[Hodakaguy]

Nice work !!
When will you be selling this one ?

I think this one will be around a while.....but you know lol

Hodakaguy