Engineerable » Automobiles http://engineerable.com Create, Design, Hack, Destroy, Recycle Thu, 19 Aug 2010 17:06:21 +0000 http://wordpress.org/?v=2.9.2 en hourly 1 Sprinter – Beds http://engineerable.com/2010/08/sprinter-beds/ http://engineerable.com/2010/08/sprinter-beds/#comments Thu, 05 Aug 2010 19:59:54 +0000 Daniel Bauen http://engineerable.com/?p=208 Initial sketches of the pull out couch designs:

Folding couch/bed: http://www.blazinbelltech.com/furniture.html#Mattress Supports:

Slat system used for boats: http://us.binnacle.com/BBQ-/-Stoves-/-Heaters-Chairs/tables/c7_22/p5739/Neptune%20SLAT%20SYSTEM/product_info.html Modular bedspring system, Froli: http://www.nickleatlantic.com/gallery1.htm Got this idea from here: http://www.expeditionportal.com/forum/showthread.php?t=20079

Mattress:

Memory foam 4in topper: http://www.overstock.com/Home-Garden/Serta-Rejuvenator-4-inch-Memory-Foam-Mattress-Topper/3298223/product.html?rcmndsrc=2

Couch/Beds, commercial:

Folding couch/bed: http://www.blazinbelltech.com/furniture.html#

]]> Initial sketches of the pull out couch designs:

Folding couch/bed: http://www.blazinbelltech.com/furniture.html#Mattress Supports:

Mattress:

Couch/Beds, commercial:


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]]> http://engineerable.com/2010/08/sprinter-beds/feed/ 1 Sprinter – Cooling and Heating http://engineerable.com/2010/07/sprinter_cooling_and_heating/ http://engineerable.com/2010/07/sprinter_cooling_and_heating/#comments Fri, 23 Jul 2010 19:38:37 +0000 Daniel Bauen http://engineerable.com/?p=205 Screens:

Simple design for a screen that goes over the window.  We made some that used magnetic strips, but they were kind of a pain to install, and the magnets tend to crack.  This seems like a better idea, because the window height can be adjusted.  Maybe build some kind of rain shield into it. http://www.sprinteraccessories.com/074_custom_bug_barrier_and_cross_ventilation_kit.html

Vent Fans:

MaxxFan [...]]]> Screens:

Vent Fans:

Circulation Fans:

Air Conditioner: Since air conditioners rely on an AC power source, I prefer to stay away from having to bring a generator, or being hooked up.  A permanently installed AC unit would be seldom used.  The best option may be a small portable AC that I can bring when I know that I will be going somewhere that has AC hookups.

Heat:

  • Espar Airtronic D2 Diesel Heater
]]> http://engineerable.com/2010/07/sprinter_cooling_and_heating/feed/ 2 Sprinter – Awning http://engineerable.com/2010/07/sprinter_awning/ http://engineerable.com/2010/07/sprinter_awning/#comments Sat, 17 Jul 2010 17:48:45 +0000 Daniel Bauen http://engineerable.com/?p=201 Crank Out Awnings:

F45 Plus Fiamma F45Ti: This is a nice awning, and the one that is usually most commonly installed on the sprinter conversions.  It has self supporting arms that allow the awning to be cranked out with ease.  I want to be able to attach the support posts to the vehicle as shown in the image. http://www.fiammausa.com/products/awnings.asp?Fam=F01 A&E [...]]]> Crank Out Awnings:

Retractable:

Retractable and Portable:

Fold up:

Awning Rails:

  • http://www.rochfordsupply.com/shop/Boating_and_Marine/Awning_Rail/Awning_Rail_-_Aluminum/index.html
  • http://www.sailmakerssupply.com/prod_detail_list/48
  • http://www.perfectfit.com/154247/products/Keder-Awning-Rail-Insert.html

Conclusion: I was fortunate enough to a used Fiamma F45 Plus (earlier model of the F45Ti) on the Sportsmobile forum in Austin Texas.  The guy had not yet sold it because everyone wanted it shipped.  My friend who lives in Austin picked it up for me.  Sweet deal!

]]> http://engineerable.com/2010/07/sprinter_awning/feed/ 1 Sprinter – Roof Rack http://engineerable.com/2010/06/sprinter-roof-rack/ http://engineerable.com/2010/06/sprinter-roof-rack/#comments Fri, 04 Jun 2010 20:07:18 +0000 Daniel Bauen http://engineerable.com/?p=178 The sprinter is already so tall, I really don’t want to add any storage space on the top.  However, I would like to install a solar panel and mounting points for an awning, or tarp hook points.

The 2006 and earlier sprinters did not come with roof rack rails.  I believe the 2007 and newer models [...]]]> The sprinter is already so tall, I really don’t want to add any storage space on the top.  However, I would like to install a solar panel and mounting points for an awning, or tarp hook points.

The 2006 and earlier sprinters did not come with roof rack rails.  I believe the 2007 and newer models have rails, or option for rails.

My initial idea for rails involved using 80/20 or similar T-slot extruded aluminum.  These are stiff, very strong, and the position can be adjusted anywhere along the length.

Later, I found out about L-Track, used for tie downs, and similar to what they use for seat tracks in airplanes.  The track is lower profile, has nice form fitting profile, and the attachments can be inserted anywhere along the track.  There are a lot of options for tiedowns that insert into the track.  Most are quick-release, but some are more permanent screw down.

An example of L-track available from Mac’s Custom Tiedowns (Summit Racing is a local distributor of their products):

End pieces are available here: http://www.macscustomtiedowns.com/product/257/All

Sealing up the underside of the track:

Hardware:

]]> http://engineerable.com/2010/06/sprinter-roof-rack/feed/ 0 Sprinter – Center Jump Seat http://engineerable.com/2010/05/sprinter-center-jump-seat/ http://engineerable.com/2010/05/sprinter-center-jump-seat/#comments Thu, 20 May 2010 19:06:35 +0000 Daniel Bauen http://engineerable.com/?p=134 The sprinter has enough space between the front seats to squeeze in an extra seat, and possibly a passenger. After much searching, I found a nice folding seat that comes from the center second row seat in a Ford Explorer. It has it’s own seatbelt, which makes installation a lot easier, and there’s [...]]]> The sprinter has enough space between the front seats to squeeze in an extra seat, and possibly a passenger. After much searching, I found a nice folding seat that comes from the center second row seat in a Ford Explorer. It has it’s own seatbelt, which makes installation a lot easier, and there’s no seatbelt hanging from the ceiling. When not needed, the seat can fold down flat and becomes a center console ( after adding console-like accessories).

Adam helped me build the first stand for it for mounting the seat. It’s a nice solid stand that’s bolted to the floor. After a week road trip, we came to the realization that it would be nice if the seat was easily removable for when only 2 people are traveling. The seat blocks easy access to the front seats. You can jump over it when it’s folded down, but most of the time you have to walk outside to access the front seats.
I couldn’t find any removable seat tracks that had the mating hardware on the seat side. A good solution for easy removable seat that didn’t require too much custom fabrication is to either use aluminum L track, or E track. L track is used in airplanes to attach the seats, allowing them to slide the seats closer together when they want to pack us in tighter. E track is mostly used as tie down. I like the E track better, because it seems easier to just drop the seat into place, and more easily releasable. L track requires you to drop and slide into place, and other than the custom aircraft seat attachments, I couldn’t find suitable quick release brackets.

The design I’ve decided on is a custom approach, using hook-rotate-locked with pin attachment.  It should be easy to construct from plate steel, strong, and not as noticeable when the seat is removed.

The following image shows how the seat can be placed in the forward facing, or reverse facing direction.  It uses pins as the attachment points.

]]> http://engineerable.com/2010/05/sprinter-center-jump-seat/feed/ 4 Sprinter Maintenance Record http://engineerable.com/2010/03/sprinter-maintenance-record/ http://engineerable.com/2010/03/sprinter-maintenance-record/#comments Sun, 28 Mar 2010 06:20:59 +0000 Daniel Bauen http://engineerable.com/?p=119 72,000 miles Purchased from DHL 72,060 3/29/2009 – engine air filter, cabin air filter, fuel filter, intercooler air intake hose replaced, engine oil change, oil filter, windshield wipers, wheels and tires (front tires are new, rear tires are approximately 70%, the tires that came with the G500 rims were too big for the front), transmission [...]]]> 72,000 miles Purchased from DHL
72,060 3/29/2009 – engine air filter, cabin air filter, fuel filter, intercooler air intake hose replaced, engine oil change, oil filter, windshield wipers, wheels and tires (front tires are new, rear tires are approximately 70%, the tires that came with the G500 rims were too big for the front), transmission fluid, transmission pan seal, transmission filter, transmission electronics plug, serpentine belt, serpentine belt tensioner (not sure if the old one was bad, because replacing it did not solve the rattling at idle problem)

72,400 Replaced waterpump.  Old water pump started leaking

74,916 4/16/2010 – Replaced factory 90A alternator with 200 Amp alternator, replaced the 2 serpentine belt idler pulleys (this eliminated the rattling at idle sound)

]]> http://engineerable.com/2010/03/sprinter-maintenance-record/feed/ 0 Sprinter – Kitchen http://engineerable.com/2010/03/sprinter_kitchen/ http://engineerable.com/2010/03/sprinter_kitchen/#comments Thu, 04 Mar 2010 21:13:58 +0000 Daniel Bauen http://engineerable.com/word/?p=62 Kitchen Overview

A well thought out kitchen is important, because it will be one of the most used areas. It should be easy to clean, seamless so that there are no cracks for gunk to accumulate, or water to leak into, and preferably the whole counter top drains water to the sink. The search [...]]]>

Kitchen Overview

A well thought out kitchen is important, because it will be one of the most used areas. It should be easy to clean, seamless so that there are no cracks for gunk to accumulate, or water to leak into, and preferably the whole counter top drains water to the sink. The search for a sink with a drainboard that had modular portions to it which could act as counter top space led to the double basin sink from Ikea. It also has a whole series of accessories that fit inside the edge and basins.

This was my idea for the design, utilizing the above sink as the counter top.

To avoid rust, needing to paint, and just because I like stainless, I bought 3/4in square stainless tubing to weld a frame. I also learned how to TIG weld while making this frame. Although it takes more practice, Tig welding is a joy, especially in the minimum (to zero) amount of grinding necessary compared to Mig welding.

The sink frame in it’s mostly finished state, with sink fitted on top.

The sink is soldered to the frame using tin/silver solder. The sink material is too thin to weld to the frame. I attempted several times on some test strips and kept burning through the thin stuff, while the thicker tubing was barely heating up. Harris Stay-Brite silver solder is recommended for soldering stainless. I chose #8, which has 6% Silver (instead of 4% for the regular) and is thicker, allowing for easier fillets and filling in gaps. A flux also needs to be used such as Harris Stay-Clean flux.

The backsplash is soldered onto the sink and frame. This leaves no cracks, and makes everything easy to clean with a wash down.

Stove Stove:

Butane stove:

Alcohol Stove:

  • The size of these stoves may better fit the drawer above the fridge.
  • Cookmate, cheaper than Origo, but seems to be of same quality: http://www.swego.com/store/pc/viewPrd.asp?idcategory=11&idproduct=4
  • Origo, distributed by Dometic:

Propane Stove:

Stove/Oven Ideas:

MicrowaveMicrowave:

Cabinets Ideas:

Kitchen Drawer Slides:
These slides already have walls. All they need is a back, front, and bottom.

Low Side Drawers: http://www.cabinetmart.com/shop/Drawer-Slides.3

http://www.rockler.com/product.cfm?page=2326

http://knobsplus.com/ecom.asp?pg=products&specific=jpqpgmf8&gotogrp=188&gotopgnum=1

High Side Drawers: http://www.cabinetmart.com/High-Metal-Drawer.714?currency=USD

Floor mounted version: http://www.rockler.com/product.cfm?page=21592

Premade birch drawer sides: http://www.rockler.com/product.cfm?page=204

Good wordworking site: http://woodgears.ca/

Water System Water Pump:

Permanently installed tanks:

Portable Tanks:

Water Recycling

For washing and rinsing dishes, a circulation pump could run the water back through the faucet or a separate sprayer.  The main problem would be filtering out food bits, because the filter element needs to be easily removable so that it can be emptied or dumped after each use.  I’m not sure how well this would work, because there’s a possibility that it could become smelly due to food residue.

]]> http://engineerable.com/2010/03/sprinter_kitchen/feed/ 0 Sprinter Urban Camper http://engineerable.com/2010/03/sprinter-urban-camper/ http://engineerable.com/2010/03/sprinter-urban-camper/#comments Wed, 03 Mar 2010 08:07:35 +0000 Daniel Bauen http://engineerable.com/word/?p=9 Sprinter

After spending some time in a VW Westfalia camper in Maui, I was determined to have one of my own, but with more power.  With our foot to the floor, grinding up the mountains of Maui, unsure of when forward progress would end and we would start rolling [...]]]>

Sprinter

After spending some time in a VW Westfalia camper in Maui, I was determined to have one of my own, but with more power.  With our foot to the floor, grinding up the mountains of Maui, unsure of when forward progress would end and we would start rolling backwards, Sprinter shuttle buses loaded with passengers would pass us at full speed.  Screw the VW, we need one of those, and it’s diesel!  Diesel VW Westfalias are quite rare.

Westfaliaing it up in Maui.

I searched around for a Westy camper when I returned.  I didn’t realize how expensive they are.  A late 80’s model in good shape is easily $15,000.  But used Sprinter’s were also expensive, and camper conversion new Sprinters are insane, costing as much as $120,000, and averaging about $80,000 depending on how thick the gold plating on the sink is.  I almost gave up the search when I came upon a DHL contractor who was liquidating his inventory of 2006 Sprinters at half the cost I was seeing them sell for used.  I managed to grab the last one.  It had relatively low miles, 71k, and other than some dings due to the load shifting around with the interior liner removed, it was in excellent condition.

I almost wish it still had the DHL logo on the side.  When I arrive somewhere, people always think that their getting a delivery.   Other than being bright yellow, it’s a stealth camper because it appears as a utility/delivery vehicle.  There’s only one window in the sliding door, and the rear doors have windows.  I don’t plan on installing anymore windows, because the more windows, the more it gives itself away as a camper.  Anyways, the visibility upfront is excellent, and I don’t plan on chilling in the camper during the day when I should be outside biking or something.  The passengers in the rear just won’t have much to see.

ToDo List of things I want to add to the Sprinter

Hood Ornament

]]> http://engineerable.com/2010/03/sprinter-urban-camper/feed/ 1 Sprinter – Hidden Wireless Keypad http://engineerable.com/2010/03/sprinter-hidden-wireless-keypad/ http://engineerable.com/2010/03/sprinter-hidden-wireless-keypad/#comments Wed, 03 Mar 2010 01:06:07 +0000 Daniel Bauen http://engineerable.com/word/?p=21 I only have one key for the yellow submarine, and I hope I don’t lose it.  I usually travel with other people, and juggling a key quickly becomes tiresome.  I learned this while camping with 4 friends in the Westy in Maui.  It’s always “Who has the key, where’s the key, can I borrow the [...]]]> I only have one key for the yellow submarine, and I hope I don’t lose it.  I usually travel with other people, and juggling a key quickly becomes tiresome.  I learned this while camping with 4 friends in the Westy in Maui.  It’s always “Who has the key, where’s the key, can I borrow the key, did you lock it”.  To avoid this problem, and allow everyone access to the Sprinter at their will, I wanted to install a keypad.  I found this keypad on ebay for $32.  The quality is quite good, and it works well.  Now, where to mount it.

I wanted the keypad to be hidden, not because I’m afraid people will hack the code, but because it’s a little ugly, and I thought it would be much nicer if its discrete.  The front license plate holder looked big and blocky, like there was enough space behind it to hide the keypad.  All I had to do was hinge it, make a stop to limit how far it could be pulled out, and make it latch closed.

]]> http://engineerable.com/2010/03/sprinter-hidden-wireless-keypad/feed/ 1 Sprinter – Insulation http://engineerable.com/2010/03/sprinter-insulation/ http://engineerable.com/2010/03/sprinter-insulation/#comments Tue, 02 Mar 2010 19:29:43 +0000 Daniel Bauen http://engineerable.com/word/?p=19 The sprinter is a tin box on wheels, and when the sun hits it, the interior metal becomes hot enough to burn you, not to mention the interior turns into an oven. Insulation of at least the roof is critical. For the roof I applied 2 layers of 3/4in foam. I used polyeurethane construction glue, [...]]]> The sprinter is a tin box on wheels, and when the sun hits it, the interior metal becomes hot enough to burn you, not to mention the interior turns into an oven. Insulation of at least the roof is critical.
For the roof I applied 2 layers of 3/4in foam. I used polyeurethane construction glue, and double sided carpet tape to hold it in place while the glue dried. The corners bends were made by scoring 3-4 times with one inch spacing between scores.

Insulating the side walls was much more time consuming than I anticipated.  Maybe it’s just because I took my time to do it.  I used the same 3/4 in foam, cut into small panels, and glued into place

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