NORDO's Camperization Project

[nxski]

Are the pleats made from the same type of material? Maybe they had to add the pleats because the grey fabric is stretchier than the red!?

[Nordo]

Are the pleats made from the same type of material? Maybe they had to add the pleats because the grey fabric is stretchier than the red!?

They are different fabrics, but when I was picking out the colors and fabric, I thought they were similar in characteristics. But that is a good point, maybe that is why. The shop that did them is closed down until the 15th, so I am going to stop in and talk with them about it. Im sure it wont be a big deal to re sew a few seams.

[Nordo]

I have not posted here for a while…and yet I have done a lot of new stuff to the Deli since I finished the interior. Thought I should post a few pics of the roof rack that I built with a friend. I built a roof rack because I have always wanted a roof top tent. I found a used Tepui tent for a great price on Kijiji!! I also bought an ARB awning and some LED lights, so I needed a rack to attach all of it to! The rack has extra storage in front of the tent for my Inflatable kayak or for extra fuel cans on real long hauls. Not sure what the weight limit is of the rack, but I have had 5 adults in the tent all at the same time with absolutely no issues!! (they were there strictly for testing!)

I made the rack out of 1 1/4 inch aluminum, but I had to enlist the help of a friend who had the equipment and know-how to show me how to weld it!! Way harder than welding steel, but after about 6 hrs of welding you start to get the basic idea!!


So here is the finished rack with the awning installed.


After I finished the rack I took it to a paint shop and had the rack powder coated! Figured it would be the most durable option and trouble free. I came out better than I could have hoped for!!


Here is the whole set up!! Took the rig out all summer long and camped all over BC, Alberta and Montana!

[macro]

That is AWESOME!!!

[almac]

very cool.
I always wanted to learn how to weld aluminum...

[FalcoColumbarius]

Nordo, that is a really nice looking job. Did you draw up plans when you conceived the idea or did you just wing it?

Falco.

[Nordo]

Nordo, that is a really nice looking job. Did you draw up plans when you conceived the idea or did you just wing it?

Falco.

Im a 'wing-it' kind of guy!! I knew what I wanted for outside dimensions and length... then I just started cutting and welding!! There really isn't much to the frame. I just welded the outer frame then added the stringers afterwards. For the mounts, I blocked the frame on top of the van where I wanted it to fit, then cut the 4" risers for each individual spot. The risers in the front are shorter than the back due to the gentle rise of the van's roof.

[thelazygreenfox]

Nordo
A first class and quality job. Powder coating your aluminum rack really "topped off" your L300.
I like the cargo cover as well.
TLWF

[macro]

Could you show an "up close and personal" pic of the gutter feet? I'm in the process of making my own and am looking for the most straightforward idea. Thanks!

[Nordo]

Nordo
A first class and quality job. Powder coating your aluminum rack really "topped off" your L300.
I like the cargo cover as well.
TLWF

Ha ha. I see what you did there!! Thanks for the nice words!!

Ill post some pics of the mounts tomorrow when the light comes back up Macro.

[Nordo]

Here is the unclose and personal shots of my gutter mount system...

I chose to go as simple as possible. Because of the weight of the tent and what is usually on my rack, I didn't figure I needed some type of locking system, but I suppose I could always order bolts with special heads that have their own tool for taking off.

I went with 3" x 1/4" aluminium flats. 3 inches gives pretty good weight distribution (I figure) and I put 4 down the gutter. The tent is mostly on the back 3 risers which is another reason I opted to go with the 4 risers rather than 3.


All I did here was drill two holes in the riser and tap them out to fit the bolts (make sure you get stainless bolts!!)


Then I took some flat iron and bent these little guys on a break and cut in slots with a milling machine. The slots are a bit unnecessary I think, but it seemed easier than trying to drill 8 precise holes.


And here is a picture of the riser all put together.


You can't see it in the pictures, but I also put a patch of felt on the inside of each riser as well. It keeps the risers from scratching the van as well as pushes the riser towards the outside of the gutter and eliminates any vibration. Its just the furniture felts you get from Canadian tire.

[macro]

So with the two screws in there, does it pull in enough that it doesn't rattle up and down? Know what I mean?

[Nordo]

So with the two screws in there, does it pull in enough that it doesn't rattle up and down? Know what I mean?

Ya I know what you mean. I have not had any problems at all with this set up. There is enough weight on the rack to hold it down, but when I fasten the rack on the gutter, I tighten the bolts just snug, then tap them upwards in the holding position just to take up any 'slack' that may be there. once they are tight, there rack will not move.

[macro]

Beauty, thanks!

[punkrawker]

Nordo, that is SICK!!!! what do you think the cost of material for your epic set is? Also bloody genius idea of putting the felts on behind the mounts to the rain gutters!!! Next time you find yourself rolling through the Calgary area let me if you wouldn't mind, gotta see that rig set up for camp. so far, best homemade rig idea I have seen yet on a delica. Mighty top shelf ideas and workmanship dude!!!

All else fails, what would you charge a guy to have a roof rack built like yours? I bet I am not the only delica owner on here who would pay for one....just sayin..