, but you're right, that's very labor intensive.
Thanks for the link. I think the modular cases have a lot of potential for storing camping gear. They're relatively easy to make, surprisingly inexpensive, not "that" heavy and super tough. I used them to haul expensive equipment around the U.S. for years in a previous career. They outlasted every vehicle we used to haul them.
Me, too. It's a fantastic piece of work, and with my own Sprinter sold, I'm living vicariously through your build.
Yes. One of our original sketches used a similar platform for the bed. I don't know how big of a space you need to span but if the width is, say, 3' or less, I would use 1/2" Baltic Birch (see note #1 below), laminate both sides with ABS and use 1/2" "U-Cap" extrusion for the edges. On the edge with the piano hinge (see note #2), I'd drill completely through the wood for each hole (you could also do every other hole depending on piano hinge) and use #8-32 x 1/2", stainless steel, pan head screws with a matching T-nut on the other side. With a little loc-tite on each screw it should withstand many miles of washboard roads. Also be careful when tightening any fastener on top of the ABS. The plastic will discolor and warp if it gets squeezed too hard.
Mike- Your Sprinter, like your Jeep, is a complete mind blower. Thanks for sharing both builds (not to mention your other cool builds) with us. Just FYI- The Sprinter was probably #5 on our list of "next vehicles". The first time I toured your Sprinter it moved up to the top. It was a big motivator in our move towards the "T1N Can".
Nathanael- I wish I had some good photos to share a "how to" for the box building. The technique is no harder than what you're already doing, just a couple extra steps for the laminate and extrusions. I didn't plan to do a write up like we did with the Tiger and, regrettably for me, I didn't document much of the build with photos. I'm kicking myself now as there were a few clever solutions we came up with that I'd like to remember for future projects.
I am not sure we could fit one, but it's too good not to keep in mind. Where do you store it, when not in use, may I ask ? Is it kept up high toward the roof or off to one side ?
But thanks for posting some details now. 
I always get a kick out of seeing what a place like Adventure Trailers charges for "home builder" accessories vs. what you'll pay for the same stuff at a normal supplier. Example: "Aircraft Grade Adjustable Track" at Adventure Trailers vs. the same thing at McMaster-Carr. The road case suppliers, thankfully, don't include the "Expo Tax".
