Monday, April 27, 2026

Pile of aluminum extrusions starts to take shape

I am building the back bench/counter and murphy bed parts out of T-slot alumunim extrusions. I am trying to minimize the total weight we add to the van so when with 1" bars, hopefully after all the bracing has been installed it will be stiff enough. I designed in Fusion and ordered all the parts pre-cut and pre-counterbored on tnutz.com. There have been some lessons learned, but for the most part everything is coming together well. I am still waiting for some of the corner brackets that will really help with stiffening the structure, they should arrive by this Wednesday. I wish I would have ordered more spare parts, but the brackets are almost more expensive than the bars. I am happy how the assembled parts fit within the van, I still need to do a lot more research about how to attach the parts to the van to make them secure in a crash.

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