Build Thread sttts's overlanding build

[sttts]

My goals:
- be able to sleep in the car, 2 persons
- form follows function, it does not have to be pretty if it is functional
- minimalism: do not waste space
- "build your SpaceShuttle on your kitchen table", everything should be either buildable in the workshop or deliverable easily through aluminium profile (Item) or iron sheet cnc providers.
- Fusion 360 it is for construction, FreeCAD for FEM.
- private project, not for commercial use. Here are the CAD files. Enjoy! (License: CC-BY-NC, Attribution-NonCommercial). If you have commercial interest, contact me.

Here is where I am. The drawer stainless steel 2mm pieces are ordered (500 Euro). The linear rails are Accuride 3308 (another 340 Euro for all 4), but I could move to DZ3507 (90kg) or DS3557 (82kg) if the 3308 are too weak (65kg).

The fridge is an Engel MT35. We happen to have one.

The aluminium profiles are 30mm Item.

The bed construction is not finished yet. With what you see, I could get to nearly 2m. No need for that as we are both much shorter.

One important goal was to use Euroboxes because there are easily available, cheap and there are plenty of sizes, and to have space for 80x60x42cm (on the picture you see 60x40x12 and 40x30x22). This is what dominated linear rail choice. With the usual 19mm ones, it would not work. Between the wheel covers there is a little more than 105cm only. So I need smaller rails, 12.7mm.

 

[sttts]

Works like a charm. Am a little proud right now

 

[Logsplitter]

Works like a charm. Am a little proud right now

View attachment 7908763View attachment 7908764

Very nice work.

 

[NoAge Hunter]

Well that looks very good

 

[sttts]

Because some asked: it‘s fixed in the airline rail through 4 of these (2 each side) with m8 skrews:

 

[Logsplitter]

Because some asked: it‘s fixed in the airline rail through 4 of these (2 each side) with m8 skrews:
View attachment 7908788View attachment 7908789

I think you could start a business making and selling these.

 

[sttts]

If anybody is interested, I linked the CAD files in the initial post (for non-commercial use).

 

[sttts]

> I think you could start a business making and selling these.

Definitely, but this is just my hobby and will stay like that.

 

[sttts]

Maybe also interesting for those who want to rebuild this or something similar: next to constructing everything in Fusion 360, the main "trick" was to use stainless steel sheets (German "Blech"). They take a lot less room for the stiffness they provide. With aluminium, I likely could not have gotten the two drawers into the available 106cm of space.

For iron sheets, there are CNC companies that can
1. (laser) cut
2. bend
3. drill (likely done before step (2)), countersink ("Senken"), create threads

I did not let them do the threads, but maybe should have. I made like 100 threads in the last days. It's tedious in stainless steel, like everything you do manually. Countersinks are the hardest. I originally tried m6 to do myself, but gave up (needs like 1000N force) and switched to 4mm, which was more feasible.

For production, I turned to https://laserhub.com/, who themselves afaik delegate the orders to local companies. For the base, 2 drawers (all 2mm) and the 6 angle brackets (in the middle, 4mm), it costed me 527 Euro including German VAT and shipping. Interestingly, the Molle pattern in one of the drawers does not cost extra. The CNC laser cutter does not care.

Then I needed the linear rails, 2 pairs costing 140 Euro each. With some more smaller stuff it should be 1000ish Euros.

Most amazing: these CNC laser cutting companies just take a step file export of the pieces, analyse them, understand which thickness the sheet has, where holes are and how many bends they need, and whether they are feasible to produce:

Two weeks after ordering you get this little palette:

Before though, it's all about time in front of CAD:

and once in a while do some verification (I used FreeCAD's FEM module to compute whether the expected forces lift up the base where connected to the Airline rails):

(this was an earlier construction without a one-piece base, but with two or three brackets. But this construction did not work out.

Happy building!