The interior of the van is/will be framed out using 8020 fractional 15 series extruded aluminum. These are 1.5 inch by 1.5 inch lengths of T-slotted anodized 6061 Aluminum.
For joining of the extrusions, we will be using 8020's interior anchor fasteners. This requires ordering the lengths with counterbores pre-machined. This in turn requires ordering the exact lengths of the extrusions (you can't cut to length).
The design tenets for the structure were:
- Maintain all fasteners accessible to allow tightening or tightness checks.
- Allow constructions of free-standing submodules to allow assembly in functional stages (e.g., garage).
- Maintain a reasonable tolerance around all components and van structure (1/8 inch generally).
After measuring 5 times, consulting drawings, agonizing over a computer screen for days, and measuring 5 more times, we completed our design.
TODO: Update with post mockup structure.
Isometric View
Plan View
Section View from Passenger Side
The Bill of Materials for the order, with cost and weights is captured in this google spreadsheet.