Jump to content


Photo

Hodakaguy's 4wd Sprinter Build - Pic Heavy!

sprinter 4wd 4x4 hodakaguy hodaka

  • Please log in to reply
290 replies to this topic

#31 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:11 PM

Continued from above...

Switches.....

I'll be installing these switches in the ceiling to control the LED lighting, they will allow me to turn the lights off, work with the door switches on the starting battery or use them while camping off the house battery.  Now to make some adapter plates so I can attach them to the ceiling.

20200321_051345-X2.jpg

20200321_051355-X2.jpg


A sheer made quick work out of knocking out some aluminum squares.

20200321_082212-X2.jpg

20200321_082655-X2.jpg


Also used the CNC plasma table to cut out a plate for my fridge power port and cig plug outlet.

20200321_075524-X2.jpg

20200321_084550-X2.jpg


Parts.....

20200321_085223-X2.jpg


Now to finish up the switch plates.  I still have to paint them before they are ready to install.

20200321_143111-X2.jpg

20200321_144147-X2.jpg

20200321_144554-X2.jpg

20200321_145402-X2.jpg

20200321_145406-X2.jpg


Powerlet and Blue Sea Cig Plugs.

20200321_152154-X2.jpg


More to come...

Hodakaguy

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#32 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:12 PM

Up early this morning and back at it.

Time to fabricate the remaining two dome light switch panels.  It's pretty easy to change the square piece of aluminum into a finished panel.  First up mark out the location you need to cut out for the switch and put the piece in the vice.

20200322_054901-X2.jpg


Using a drill I made 4 holes in each corner of the inside of the cutout area.

20200322_055022-X2.jpg


Now I used a jig saw to cut out the center area and follow the lines until I have a square.

20200322_055103-X2.jpg

20200322_055414-X2.jpg


Now use a washer to mark out the curve for the corners.

20200322_055818-X2.jpg


Then use the disk sander to make quick work of rounding the corners down to the marked line.

20200322_060209-X2.jpg


Now just drill the mounting holes, sand the piece and paint.

20200322_060209-X2.jpg

20200322_092816-X2.jpg

20200322_093004-X2.jpg

20200322_144956-X2.jpg


This is the power panel I'll use to power the fridge plus whatever else we need to plug in.   I'll use a Powerlet port for the fridge instead of a US cig plug.  The Powerlet is awesome as it snaps in when you plug something into the port and you don't have to worry about the fridge coming unplugged like a US cig plug when bouncing down a gravel road for miles on end.

20200322_145012-X2.jpg

20200322_145017-X2.jpg


For the 3 way dome light switch I'm using a double pole double throw switch.  I was asked how I will wire the dome lights from two separate power sources so here's a quick sketch using these switches.    The switches will allow each section of ceiling lights to be either:  OFF, operated via the door from the starting battery or manually operated from the house battery.   I like options :).


Back to insulation work.   Cutting more 3M Thinsulate.  A good pair of sharp serrated scissors is a must here to get a clean cut on the insulation, forget trying to use an razor knife etc.

20200322_110918-X2.jpg


Hodakawife doing an awesome job insulating the rear doors.

20200322_123320-X2.jpg


Can't tell it here but she worked insulation up inside all of the nooks and crannys.

20200322_143706-X2.jpg


Last year at the Adventure Van expo is Oregon (not overland expo as it says in the pic) my son came back to the van from visiting a vendor and had this piece of Thinsulate with him that the vendor had given him, he said it was to help with the buil .   I saved it and it's time to give it a home in the drivers rear door :).   He was pretty happy today to see it getting installed.  :)

20200322_112641-X2.jpg

20200322_113014-X2.jpg

20200322_143833-X2.jpg


Continued Below...

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#33 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:12 PM

Continued from above...

I'm going to re-use the lower plastic factory panels so they went right back on.  I'll have matching custom panels for the upper parts of the doors.

When removing the door go very slow and use a propper panel removing tool so you don't break any clips or the panel itself.  Here's a shot of the back side of the panel so you can see where all the clips are located.

20200322_143827-X2.jpg


And back on the van.

20200322_144003-X2.jpg

20200322_144253-X2.jpg


Fishing the insulation In behind the L-track.

20200322_105207-X2.jpg

20200322_120509-X2.jpg


Cleaning up the factory wiring and making sure it will sit behind the wood strip when the panels go up.  Adding a bit of loom here and there to ensure no chaffing points.

20200322_123248-X2.jpg

20200322_134420-X2.jpg

20200322_134625-X2.jpg


More to come....

Hodakaguy

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#34 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:13 PM

Stickers baby!...In  case anyone wants a shot of my ugly mug on their vehicle Etc. Lol.   My buddy wants me to start a "I spotted Hodakaguy" setup where people tag me with a pic when a sticker is spotted in the wild.  I've had several requests for these so figured it was time to get the ball rolling and have some made :-)

Now when I travel I can leave my mark :-)

20200324_160702-X2.jpg

Hodakaguy

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#35 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:14 PM

Collecting parts.....

Received the Sprinters LED lighting, 6 Baja Designs LP9 Lights.......Going to be like having my own sun with me!   I'll be running 4 of the Pro Spot's and 2 of the Racer editions.  Gonna have to run some good wire, these babies will pull 55 amps!

20200327_100857-X2.jpg


I have this mystery box on it's way to me now.....maybe the lights will be mounted here?  We shall see :-)

IMG_20200326_110845_979-X2.jpg


Next up...go snag my van back :-).   My buddy Mike at VanLab cut my interior panels on his CNC machine and covered them for me in automotive tweed, the van has been living at Mikes for the past few days. while Mike performed his magic.  For the fabric I chose a dark grey automotive tweed that matches the factory plastic and a lighter tan color that matches the body paint for the ceiling, makes a great two tone look.   Since our van is a passenger model we are able to re-use the oem plastic window trim for a nice factory look.  Mike does great work, if your needing any van interior work done I would highly recommend VanLab.

Van loaded with panels.

20200327_114532-X2.jpg


Panels loaded up and another 20' of Thinsulate ready to go into the ceiling soon.

20200327_115107-X2.jpg


A few pics of the interior as Mike was fitting it up...these shots are with the panels just loose and not set in place yet.

IMG_20200327_132331_654-X2.jpg

IMG_20200327_132331_657-X2.jpg

IMG_20200327_132331_668-X2.jpg

IMG_20200327_132331_667-X2.jpg


Mikes CNC router where the magic happens -)

20200327_112319-X2.jpg


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.

20200327_145057-X2.jpg


Installing some Thinsulate in the wells

20200327_145321-X2.jpg


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

20200327_145545-X2.jpg


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

20200327_145640-X2.jpg


And all sealed off with some Sikaflex 221

20200327_145743-X2.jpg


And plastic re-installed.

20200327_151033-X2.jpg


Continued Below...

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#36 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:15 PM

Continued from above...

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

20200327_151912-X2.jpg


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.

20200327_151949-X2.jpg

20200327_152016-X2.jpg


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

20200327_152114-X2.jpg

20200327_152156-X2.jpg

20200327_153501-X2.jpg


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

20200327_153456-X2.jpg

20200327_153905-X2.jpg

20200327_153915-X2.jpg

Lookin Good!

Lots more to come.....

Hodakaguy

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#37 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:16 PM

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.

20200328_090135-X2.jpg


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

20200328_090146-X2.jpg

20200328_090305-X2.jpg


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.

20200328_091132-X2.jpg


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 :-)

20200328_091442-X2.jpg

20200328_091618-X2.jpg


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

20200328_091713-X2.jpg

20200328_091850-X2.jpg


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

20200328_092209-X2.jpg


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

20200328_093345-X2.jpg


And a jig saw to cut out the wood area.

20200328_093634-X2.jpg


And installed.  This should work great for the kiddo :-)

20200328_095508-X2.jpg

20200328_095814-X2.jpg

20200328_095821-X2.jpg

20200328_095837-X2.jpg


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

20200328_100356-X2.jpg


More to come...

Hodakaguy

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#38 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:17 PM

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!

20200402_134850-X2.jpg


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

20200402_135510-X2.jpg


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

20200402_140229-X2.jpg


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

20200402_141535-X2.jpg


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)

20200403_044354-X2.jpg


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

20200402_153914-X2.jpg

20200402_153923-X2.jpg



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.

20200402_172512-X2.jpg

20200402_172523-X2.jpg

20200402_172443-X2.jpg

20200402_172414-X2.jpg

20200402_172402-X2.jpg

20200402_171557-X2.jpg


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!
 
20200402_172601-X2.jpg

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

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#39 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:17 PM

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. :-)

20200404_085329-X2.jpg

20200404_102234-X2.jpg

20200404_105401-X2.jpg


Trying to catch as many of the aluminum shavings as possible :-)

20200404_103405-X2.jpg


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.

20200404_105308-X2.jpg


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.

20200404_113819-X2.jpg


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.

20200404_121424-X2.jpg


Then a piece of 1" stock used to mark center

20200404_115559-X2.jpg

20200404_115608-X2.jpg

20200404_115926-X2.jpg

20200404_120724-X2.jpg


And mounted up.  Lots of built in cooling

20200404_133429-X2.jpg

20200404_133508-X2.jpg


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.

20200404_133231-X2.jpg


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

20200404_133841-X2.jpg

20200404_134138-X2.jpg


Hodakaguy

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE


#40 Hodakaguy

Hodakaguy

    Senior Member

  • Members
  • 641 posts

Posted 23 May 2020 - 08:18 PM

Time to start running the wiring....lots of wiring!

First up I loosened up the rack and lifted it up on one side to get clearance for the cable gland install.

20200405_111309-X2.jpg


To pass the wires through the roof of the van I'll be using two SeaView Cable Glands with the metal powder coated caps, these are marine units and work really well to keep water out.   I've used these cable glands on numerous builds and have yet to have one leak.

20200405_103445-X2.jpg


The cable gland broken down.   The kit comes with pieces of brass tubing that you chuck up in a drill and basically melt a hold through the rubber compression fitting.   The tubing leaves a nice clean hole, don't use a drill bit as it will NOT leave a clean hole in the rubber.

20200405_103841-X2.jpg


Pic the correct size of tubing for your wire diameter and drill the holes where you need them.

20200405_104504-X2.jpg

20200405_104551-X2.jpg


Holes drilled...ready to install on the van.

20200405_114847-X2.jpg


Test fitting for location...yep right about here will do.

20200405_115700-X2.jpg

20200405_115707-X2.jpg


Using a right angle drill to drill a pilot hole on each end of the cable gland base.   Once the base is anchored in place with two screws use a drill bit to mark the holes for the wires by slightly drilling through each hole in the rubber bushing to create a mark on the roof, then remove the cable gland and drill pilot holes for the wires.

20200405_120137-X2.jpg


Using a Unibit to open up the holes for the wires to pass through.

20200405_120830-X2.jpg


Now to use the de-burring tool to take the sharp edges off the holes.

20200405_123017-X2.jpg

20200405_123005-X2.jpg


Holes drilled.

20200405_124159-X2.jpg

20200405_124615-X2.jpg



Didn't get a pic but I painted the bare edges on the holes.   Next up time to assemble the cable gland.   I have always added some Sikaflex 221 to the base to ensure a waterproof seal.

20200405_124730-X2.jpg

20200405_125011-X2.jpg


I also add 221 to the stainless screws that attach the base to the roof.

20200405_125114-X2.jpg


Continued Below....

 


  • 0

My 4wd Sprinter Build: CLICK HERE

My Unimog U1300L Build:  CLICK HERE

My VW Syncro Westy Build:  CLICK HERE

My Tacoma/FWC  Builds: CLICK HERE

Ride Report - In Memory Of The Crewmen: CLICK HERE






Also tagged with one or more of these keywords: sprinter, 4wd, 4x4, hodakaguy, hodaka

0 user(s) are reading this topic

0 members, 0 guests, 0 anonymous users