Dave's '04 AWD Camper Build

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3rd Row Seat - Folding Plywood Platform

Postby dmilamj [OP] » February 19th 2016, 6:48pm

So I started work on the folding plywood platform portion of the seat. The idea is to have two panels that are hinged off the front edge of the seat base and that fold up underneath the seat.

Here's test fitting the plywood and hinge location.
Image

Here are the 3/4" plywood panels, 16" deep each and about 47" wide. I've routed the edges except along the hinge side. The hinges are standard steel door butt hinges, $10 at the hardware store. I had to route a little channel for the hinge barrel as well as mortise the hinge plates.

Chisel for scale:
Image

Test fitting underneath the folding platform:
Image


Cut out the stock mounting point threaded plates:
Image


Weld in some angle for a flat mounting point for the hinges:
Image


Test fit base with folding platform extended:
Image

Test fit folded:
Image


More to come....
Original Poster [OP]
dmilamj
Fueling (1/4 tank)
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Years of Membership: dmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full years
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Joined: September 2015
Gender: Male
Alias (AKA): Dave
Van Model Year: 2004
Van Make/Model: Chevrolet Astro
Extra Info: AWD

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Re: Dave's '04 AWD Camper Build

Postby Lumpy » February 19th 2016, 9:20pm

This is really a great project.

:clap: :clap: :clap:

Doesn't this just beat the heck out of going down to the new car dealer, forking over $960 a month for the next eleven years and getting in return a car that looks like every other car in the neighborhood? And smells like Chinese rubber on top of all that.


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Re: Dave's '04 AWD Camper Build

Postby dmilamj [OP] » March 21st 2016, 3:50pm

I'll update the seat build in a bit with some more photos, but I've got a quick question:

I'm thinking of attaching my house battery at an angle in front of the rear wheel hump. I need to attach a battery tray to the sloping part of the rear drivers wheel hump. Any thoughts about the best way to do that? I was thinking bolts with a fender washer to attach the tray through the wheel hump sheet metal. There would be a visible bolt/fender washer inside the wheel well. Is that an issue? If the tire gets up that high, it would be a bad rub to have a bolt sticking out. I will trim the bolts to get them as short as possible.
Original Poster [OP]
dmilamj
Fueling (1/4 tank)
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Years of Membership: dmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full yearsdmilamj has been a member for 5 full years
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Joined: September 2015
Gender: Male
Alias (AKA): Dave
Van Model Year: 2004
Van Make/Model: Chevrolet Astro
Extra Info: AWD

Re: Dave's '04 AWD Camper Build

Postby Lumpy » March 21st 2016, 4:01pm

Insert the bolt from the outside, in the wheel well. The tire will never get up that close. That's like 1/4" from the inside of the wheel well. If the wheel/tire moves that much, you've got other, boinker problems.

The obvious problem is the compound concave, convex curves of the wheel well. I suppose you could build complex curve surface washers for the inside and outside. Cargo will be along in a minute to explain how to do that. But I think simpler is to disregard the curves, use regular diameter washers (not fender washers) and distribute the stresses between three points. Nylon washers under the steel, RTV sealer, torque them not TOO tight, drive it.


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Re: Dave's '04 AWD Camper Build

Postby deafman » February 15th 2021, 8:36am

We haven't seen a post from you in a few years Dave. How are you and the van?
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Re: Dave's '04 AWD Camper Build

Postby sixsix » February 15th 2021, 5:08pm

HE WAS JUST VISITING THE OTHER DAY... WHY NOT PM HIM AS I DOUBT HE CHECKS IN OFTEN.
.

"Ban gerrymandering" out 1 side, then says, "We really need to get rid of the electoral college for starters, there is no way in hell that the person that receives fewer votes wins, simply crazy."
So only CAL, ILL & NY Elects??
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Re: Dave's '04 AWD Camper Build

Postby AstroWill » February 15th 2021, 8:56pm

That is a sweet van that Dave has. Low mileage, great year, pop-top.

Dave, hope you are out there in the wild enjoying life and your van!

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Report terrorists and anyone inciting violence to FBI @ fbi.gov and 800-CALLFBI (225-5324)
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