Hodakaguy's 4x4 Sprinter Build
- Thread starter Hodakaguy
- Start date
Hodakaguy
Adventurer
Thanks. There just isn't a way to do wiring quickly where it doesn't look like it was done quickly lol.
Hodakaguy
Hodakaguy
Adventurer
Headliner Installation........and lights baby!
Started out this morning by cutting some pieces of select pine on the table saw to install under the fans. I should have installed these when I originally installed the ceiling fan units. The boards will serve two functions, first they will give me something anchor the ceiling panels into and 2nd they give the fan screws more of a secure bite.
Also have to have the morning coffee
Next up removing the fan units from the bases.
I removed the screws on the front and back ends of the fan base, next up get the wood into position. A quick clamp came in handy here.
I put some Sikaflex 221 in each screw hole and on each screw itself.
When I originally installed the fans I used Sikaflex 252 to seal the fans to the van roof and it's very solid. As long as the fans are off I decided to add an extra layer of leak protection by adding a coat of Dicor lap sealant.
Got a sweet picture of my Mandels (Socks and Sandles)
Insulation re-installed around the fan.
Thinsulate SM600L
Continued Below...
Hodakaguy
Started out this morning by cutting some pieces of select pine on the table saw to install under the fans. I should have installed these when I originally installed the ceiling fan units. The boards will serve two functions, first they will give me something anchor the ceiling panels into and 2nd they give the fan screws more of a secure bite.
Also have to have the morning coffee
Next up removing the fan units from the bases.
I removed the screws on the front and back ends of the fan base, next up get the wood into position. A quick clamp came in handy here.
I put some Sikaflex 221 in each screw hole and on each screw itself.
When I originally installed the fans I used Sikaflex 252 to seal the fans to the van roof and it's very solid. As long as the fans are off I decided to add an extra layer of leak protection by adding a coat of Dicor lap sealant.
Got a sweet picture of my Mandels (Socks and Sandles)
Insulation re-installed around the fan.
Thinsulate SM600L
Continued Below...
Hodakaguy
Hodakaguy
Adventurer
Continued from above.....
Two more layers of pine to bring the boards down to the correct height for the ceiling panels, Had to take about 1 blades width off the last board on each section to get the correct height.
Ready for the center ceiling panels.
Here I'm using a piece of heated metal to melt holes in the ceiling panel where I'll install the screws to anchor the panels in place. By melting a hole before you drill you keep the fabric from fraying.
And screws installed.
Testing the lights.....Everything worked, sweet! Lights operate off the door switch with the ceiling switch in position 1 and manually off the aux battery in position 2.
Video showing the function of the LED touch lights.
<iframe width="560" height="315" src="" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>
Still need to install the trim rings and touch up a few small items then I can move on to other areas.
More to come....
Hodakaguy
Two more layers of pine to bring the boards down to the correct height for the ceiling panels, Had to take about 1 blades width off the last board on each section to get the correct height.
Ready for the center ceiling panels.
Here I'm using a piece of heated metal to melt holes in the ceiling panel where I'll install the screws to anchor the panels in place. By melting a hole before you drill you keep the fabric from fraying.
And screws installed.
Testing the lights.....Everything worked, sweet! Lights operate off the door switch with the ceiling switch in position 1 and manually off the aux battery in position 2.
Video showing the function of the LED touch lights.
<iframe width="560" height="315" src="" frameborder="0" allow="accelerometer; autoplay; encrypted-media; gyroscope; picture-in-picture" allowfullscreen></iframe>
Still need to install the trim rings and touch up a few small items then I can move on to other areas.
More to come....
Hodakaguy
Last edited:
Hodakaguy
Adventurer
Hodakaguy
Adventurer
No Didn't do anything to the wood, it's living in a nice environment and out of the eliments.
Hodakaguy
Hodakaguy
Adventurer
Playing with the camera today.....
Coffee while on the road! Here's a quick video demonstrating the Presto Myjo coffee press. We've used this press for quite a while now and love it, it's quick to use and there is almost zero clean up! The unit is small, light weight and very inexpensive. Works awesome in conjunction with the Jetboil....hot fresh coffee in 2 minutes!
Link to the MyJo on Amazon: CLICK HERE
Link to the Peak Refuel Chicken Alfredo on Amazon: CLICK HERE
Link to the Coffee we use (French Roast) on Amazon: CLICK HERE, Variety Pack here: CLICK HERE
Link to the Jetboil Flash Stove on Amazon: CLICK HERE
Hodakaguy
Coffee while on the road! Here's a quick video demonstrating the Presto Myjo coffee press. We've used this press for quite a while now and love it, it's quick to use and there is almost zero clean up! The unit is small, light weight and very inexpensive. Works awesome in conjunction with the Jetboil....hot fresh coffee in 2 minutes!
Link to the MyJo on Amazon: CLICK HERE
Link to the Peak Refuel Chicken Alfredo on Amazon: CLICK HERE
Link to the Coffee we use (French Roast) on Amazon: CLICK HERE, Variety Pack here: CLICK HERE
Link to the Jetboil Flash Stove on Amazon: CLICK HERE
Hodakaguy
Hodakaguy
Adventurer
Time to get the roof rack finished up so I can move back to doing inside work....
Next on the roof rack...close in these side gaps so you don't see the white bottom of the solar panel. I'll also build some filler pieces that cover the gaps on each side of the solar panel for aesthetics reasons.
Here's the gap that I'll be fabricating a cover for on each side.
Dialing in the pattern with FAD.....Foam Aided Design. I used the foam board to get a good fit up before transferring the pattern to Aluminum.
Pattern transferred to a sheet of 1/8" aluminum. I was playing with design ideas here and had drawn in a few circles, I decided not to incorporate the holes as I have another idea that I'll add in down the road.
Steady hand and a Jig Saw.....cut baby cut.
Making the 2nd side.
Making some spacers with some 1/2" x 2" aluminum 6061-T6 stock.
Chop saw with aluminum blade made quick work of cutting the aluminum stock....nice and clean.
Head of a bolt makes a good tool to mark the corners before grinding.
Getting ready to drill the mounting holes.
Now to make up the solar panel end gap covers. Starting with some nice aluminum bits
You can see the gaps on each end of the panel in this shot that I'll be covering.
Drilling holes and using pop rivets to attach the aluminum angle to the aluminum sheet. The angle will keep the aluminum sheet from panting in the wind, making it nice and solid.
Continued Below....
Hodakaguy
Next on the roof rack...close in these side gaps so you don't see the white bottom of the solar panel. I'll also build some filler pieces that cover the gaps on each side of the solar panel for aesthetics reasons.
Here's the gap that I'll be fabricating a cover for on each side.
Dialing in the pattern with FAD.....Foam Aided Design
. I used the foam board to get a good fit up before transferring the pattern to Aluminum.
Pattern transferred to a sheet of 1/8" aluminum. I was playing with design ideas here and had drawn in a few circles, I decided not to incorporate the holes as I have another idea that I'll add in down the road.
Steady hand and a Jig Saw.....cut baby cut.
Making the 2nd side.
Making some spacers with some 1/2" x 2" aluminum 6061-T6 stock.
Chop saw with aluminum blade made quick work of cutting the aluminum stock....nice and clean.
Head of a bolt makes a good tool to mark the corners before grinding.
Getting ready to drill the mounting holes.
Now to make up the solar panel end gap covers. Starting with some nice aluminum bits
You can see the gaps on each end of the panel in this shot that I'll be covering.
Drilling holes and using pop rivets to attach the aluminum angle to the aluminum sheet. The angle will keep the aluminum sheet from panting in the wind, making it nice and solid.
Continued Below....
Hodakaguy
Hodakaguy
Adventurer
Continued from above....
Starting to assemble....
Tucking the LP9 wiring harness up under the solar panel.
Starting to assemble the side and top pieces.
Wiring all tucked up and in place.
Tidying up the wiring on the back side of the drivers side panel
Solar side gap pieces installed
I think the front looks better with the side panels installed....Done!
Took the van for a drive to make sure adding the new panels didn't cause any new wind noise....nope, perfect!
Next up I'm installing a Pelican case to carry our light weight camping chairs, ground cloth etc. The case will be going right behind the solar panel as this area won't be utilized for much and its a perfect place to mount the case out of the way. I'll always have our chairs ect with us everywhere we go.
I'm using the Pelican Storm Case IM3410. These cases are super tough, water tight and lockable. They also hold up well when left outside, I had a similar case on our Syncro and it was very handy!
I used stainless steel sidewalk bolts to attach the case to the rack. I drilled holes through the case and used Sikaflex 221 to seal the bolts to the case to ensure the case stays 100% waterproof.
Quite a bit of storage inside for light weight items.
Double 1" fender washers on the under side, nice and solid.
The latches are easy to use and the case is lockable. Handy setup!
One last chore for the day...Brakes. For the last year I occasionally get a squeal from the brakes when stopping and it's driving me crazy. I pulled the front pads on both sides, cleaned them, applied lube to the critical areas then applied some "Disk Brake Quiet" on the back side of the pads......took a test drive and it's nice and quiet now
More to come...
Hodakaguy
Starting to assemble....
Tucking the LP9 wiring harness up under the solar panel.
Starting to assemble the side and top pieces.
Wiring all tucked up and in place.
Tidying up the wiring on the back side of the drivers side panel
Solar side gap pieces installed
I think the front looks better with the side panels installed....Done!
Took the van for a drive to make sure adding the new panels didn't cause any new wind noise....nope, perfect!
Next up I'm installing a Pelican case to carry our light weight camping chairs, ground cloth etc. The case will be going right behind the solar panel as this area won't be utilized for much and its a perfect place to mount the case out of the way. I'll always have our chairs ect with us everywhere we go.
I'm using the Pelican Storm Case IM3410. These cases are super tough, water tight and lockable. They also hold up well when left outside, I had a similar case on our Syncro and it was very handy!
I used stainless steel sidewalk bolts to attach the case to the rack. I drilled holes through the case and used Sikaflex 221 to seal the bolts to the case to ensure the case stays 100% waterproof.
Quite a bit of storage inside for light weight items.
Double 1" fender washers on the under side, nice and solid.
The latches are easy to use and the case is lockable. Handy setup!
One last chore for the day...Brakes. For the last year I occasionally get a squeal from the brakes when stopping and it's driving me crazy. I pulled the front pads on both sides, cleaned them, applied lube to the critical areas then applied some "Disk Brake Quiet" on the back side of the pads......took a test drive and it's nice and quiet now
More to come...
Hodakaguy
Farfrumwork
Well-known member
Clean work as always! Big improvement with those sides filled in.
I'd like to have a powder coating setup -that would be handy.
I'd like to have a powder coating setup -that would be handy.
Hodakaguy
Adventurer
Depending on how you park that's possible. If the sun is low on the horizon and behind the van you'll definitely get some shadowing.