Step one. Bought the van.
Hello Everybody, First post. I camp a lot in tents but after spending three days straight in a tent in the rain at Dolly Sods I swore I'd make a change. Here it is. Bought it Wednesday. Dro...
Forum Discussion
While I do love biking, hiking and camping, this van isn't going to convert itself. Back to work.
Sofa-bed continued:
In my last posting I'd finished a rebuild of the Center Support.
I had to also make a new Middle Brace for the new support since the support's position will change.
The Middle Brace is 3" high so cut a "corner block" to match. Because of the hardware attached to the Center Support some modifications have to be made to fit the corner block.
First problem is the bolt on the side of the support.
Use the router to cut a notch in the corner block so the block will fit over the bolt.
The corner block will be permanently attached (screwed and glued) to the Middle Brace. So It can disassembled, bolts will be used to attach the block to the Center Support. Since the block is only 3" long I don't have much leeway in were I can place the bolts.
One bolt has to go through the top metal angle. Problem is the bolt head would interfere with the movement of the square tube.
So I'll have to cut a notch int he metal angle for the bolt head. Only way I know to do this is to partially disassemble the Center Support that I just got done building. Since I used the grinder to cut off the excess threads from the bolts I want to keep the bolts in orders.
Notch out the metal angle just enough for the bolt head to clear.
Test fit looks OK.
Second problem. The head of the second bolt will hit the locking pin.
That one's easier to fix. Use a wood bit to countersink the bolt head.
Now to find the new location for the Center Support. Put the previously built battery box in it's intended position. Use it to guide the Center Support's placement. Check that there's enough room to remove the acrylic top so to service the batteries.
Once the Center Support is lined up and level -
clamp the center block to the Middle Brace and screw into place.
Follow similar steps for re-positioning the Center Support to the front Kick Board.
Looking at the Kick Board this pic shows how far I've moved the Center Support to the left.
This change in position is because when I first laid out the design for the sofa-bed I had no idea how the drive mechanism would work. Now I do.
Bolt and clamp the bed platform into place and check alignments.
Change of subject.
Last weekend on the Appalachian Trail within the Great Smoky Mountains Nation Park.
View from Charlies Bunion.
I hear it doesn't start to get crowded until this week.
Sofa-bed continued:
In my last posting I'd finished a rebuild of the Center Support.
I had to also make a new Middle Brace for the new support since the support's position will change.
The Middle Brace is 3" high so cut a "corner block" to match. Because of the hardware attached to the Center Support some modifications have to be made to fit the corner block.
First problem is the bolt on the side of the support.
Use the router to cut a notch in the corner block so the block will fit over the bolt.
The corner block will be permanently attached (screwed and glued) to the Middle Brace. So It can disassembled, bolts will be used to attach the block to the Center Support. Since the block is only 3" long I don't have much leeway in were I can place the bolts.
One bolt has to go through the top metal angle. Problem is the bolt head would interfere with the movement of the square tube.
So I'll have to cut a notch int he metal angle for the bolt head. Only way I know to do this is to partially disassemble the Center Support that I just got done building. Since I used the grinder to cut off the excess threads from the bolts I want to keep the bolts in orders.
Notch out the metal angle just enough for the bolt head to clear.
Test fit looks OK.
Second problem. The head of the second bolt will hit the locking pin.
That one's easier to fix. Use a wood bit to countersink the bolt head.
Now to find the new location for the Center Support. Put the previously built battery box in it's intended position. Use it to guide the Center Support's placement. Check that there's enough room to remove the acrylic top so to service the batteries.
Once the Center Support is lined up and level -
clamp the center block to the Middle Brace and screw into place.
Follow similar steps for re-positioning the Center Support to the front Kick Board.
Looking at the Kick Board this pic shows how far I've moved the Center Support to the left.
This change in position is because when I first laid out the design for the sofa-bed I had no idea how the drive mechanism would work. Now I do.
Bolt and clamp the bed platform into place and check alignments.
Change of subject.
Last weekend on the Appalachian Trail within the Great Smoky Mountains Nation Park.
View from Charlies Bunion.
I hear it doesn't start to get crowded until this week.
