The bed frame is composed of two horizontal rails that run fore-aft in the van and three ikea skorvas that run side to side and mate with slots machined in the rails.
The bed was intended to be adjustable in height, so L-track was mounted vertically in two locations on each side of the van at locations with structural ribs. The horizontal rails attach to the L-track. This is the trickiest part of the build. If the bed is not intended to be adjustable, the rails could bolt directly to the sides of the van using plusNuts or through bolts.
Materials:
- 1"x2" 6061-T6 Aluminum Rectangle 6' (2) - this will determine the width/length of the bed along the vehicle.
- Ikea Skorva (3) - these were chosen because they are cheap and adjustable in length to any width across the vehicle.
- L-track (4) - the length of these will be determined by the maximum and minimum bed height desired. Ours are about 2.5'.
- L-track stud fitting and locknut (4) - these will be used to attach the horizontal rails to the L-track.
- Bed Slats - these will run between the skorvas oreinted along the vehicle length (we haven't built ours yet).
- 1/4-20 plusNuts - these are used to mount L-track to the van structural ribs
- 1-4-20 fasteners
Part 1: Mount vertical L-track
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Position the L-track using clamps. The L-track should forced by the clamps to conform to the curvature of the van. Using 50" clamps in a spreader mode with some 2x4s will accomplish this. It is important to make sure that all the vertical tracks are parallel to each other and arranged so that the stud fittings can be aligned at the same height.
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Center-punch the van ribs in the center of the L-track mounting holes. Its helpfull to repeatedly punch to make sure you get a good divet to prevent the drill from walking.
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Remove the L-track.
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Drill 3/8 holes using a step bit in the punched locations. Its a good idea to touch up the holes with a self etching primer (Rustoleum makes a spay can product).
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Install plusNuts
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Use the clamps again to arrange and force the L-track into position.
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Install the L-track using 1/4-20 fasteners
Part 2: Fabricate horizontal rails
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Install an L-track stud fitting into each piece of vertical L-track at the same vertical location.
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Measure the distance between the studs (center to center) on the passenger and driver side. Ideally these will be the same distance on both sides.
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Measure out the same distance on the 1x2 aluminum rectangle, center-punch, and drill straight through both walls of the rectangle. The L-track stud fittings are 5/8, so you can start there or oversize to give a little slop. Over side the hole that will be facing into the van (away from the wall) using a hole saw bit. This hole must be large enough to get a socket though for when you attach the rectange to the stud fitting.
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Test fit the aluminum rectangle rails. You might need to do a little dremeling based on how precise your measurements and driller were.
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Determine where the skorvas need to go, ideally one in the center of the rails and two equidistant near the edges of the rails.
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Mark the edges of the slots that the skorvas will mate into. I recommend placing the slot about 1/8 inch from the inboard side of the rail. The slots on one rail need to be aligned and opposite of the slot on the other rail.
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Remove the rails.
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Drill a 1/8" hole at each end of where the slot will be into the rail.
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Using a dremel with the offset cutting guide, machine the slot between the two holes.
Part 3: Assemble
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Re-attach the rails.
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Insert the skorvas.
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Put your plywood or slats on top of the skorvas.
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Relax.
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