When I returned from CO, I had about three weeks before my van should arrive. I was focused on the items that I needed to do to be prepared to work on the van when it arrived.
While in CO, I watched several videos on how to assemble AL extrusion. I’m glad I spent that time, because I learned a few things that were going to help me with the fabrications I had designed. I found a better and simpler method to make some of the connections, but had to order some different fasteners and tools (drill fixture and tap) to do it. I ordered them on my first day back home.
While I waited for the new fasteners and tools, I got organized about the first set of tasks that I would preform on the van. I made sure that I had identified the best instructional videos that I could find on each step. I also ordered some materials that I needed (sound deadening material, insulation, sealant, glue, etc.). I will have about three weeks to work on the van after it arrives before I leave for a two-week bike tour around New Orleans with a couple of friends. I wanted to prepare enough materials, supplies, and process videos to take full advantage of those three weeks.
After the new fasteners arrived, I had to wait a few days before I could start working in the garage, because it was very cold. I don’t have a heater in the garage. I spent some time continuing to research different aspects of the van.
I also spent some time watching clips from the old Red Green show, just to put me in the right handyman frame of mind. Here’s one for you: https://www.facebook.com/share/r/1eqgaEFNNC/?mibextid=wwXIfr
On February 24th, it warned up into the upper 50’s, so I started working on the AL extrusion fabrications. I changed out the blade on my new chop saw – replacing the stock saw blade that is designed to cut wood with a blade that is designed to cut metal. Then I cut up most of the metal to make the bench seat. It didn’t take long, since in my preparations I had created a complete cut list.
I wanted to start drilling and tapping holes in the extrusion, but I was missing the correct size drill bit. Not sure why I didn’t order it when I ordered the drill fixture, but I was left with needing to go to the hardware store for one. Unfortunately, I was covered with AL shavings and I didn’t want to track them all over the house, so I spent some time cleaning up the garage and jumped in the shower.
By the time I returned from the trip to the hardware store, I decided to call it a day and pick it back up tomorrow. I knew that if I continued that I would make another mess. And I feel like I have plenty of time to work on this fabrication.
The next day, I worked about five hours on the bench fabrication. I tapped the center hole in several pieces, and drilled many holes that will be used to access bolts. The time I spent watching YouTube videos on this process really helped me. I did discover a few mistakes on my cut sheet that made me re-cut a couple of pieces. I quickly got the hang of working with the extrusion and was able to get the bench frame assembled.
There is going to be a sliding section on the bench that will convert it to a twin bed. I’ll start working on that sliding section next.
I took a couple of days off. But on the 28th I tested out the drawer slides I had bought. The standard M6 screws interfered with the slide mechanism. So, I was off to the hardware store to find a different M6 screw with a shorter head. I also made the spacers that I needed for the sliding section. In my office, I purchased three different latch mechanisms to test out for the drawers. I hope to use the best one throughout the van.
On March 1st I spent a couple of hours and finished the rest of the work that I could do on fabrications before I actually take delivery of the van. I was able to attach the drawer slides to the AL extrusion. I also fabricated the slide-out portion of the bed. So, I now just have to wait for the van.
Ford had emailed me on January 9th that my van would be built the week of February 24th and that they would let me know when it was built. However, I have not received any emails from them. So, I don’t know the status. I’m just trying to be patient.