Van racking is basically just trim carpentry with loads of scribes, using elements of North American face frame construction and European box systems of cabinet making. But it’s also an exercise in extreme organization. Getting it right can save you time and energy on the jobsite—both of which lead to increased productivity and profits. I’m a lead carpenter—if it’s wood, I do it.

From framing roofs to trim carpentry, kitchens, cabinet making and housed string staircases. My van racking system must carry any subset of tools. (Note: Click any image to enlarge)The make and model of a van is immaterial to the process of van racking. The van in this article is an LWB Trafic—slightly smaller than a standard Merc Sprinter. Racking a moving toolbox is typically done with ply, 2x and 1x. (If you want a “pimp my van” job, you’ll have to spend your own money!). Security: Shake, Rattle, and Roll In heavily populated areas, parking is often far away from the jobsite.

Ply lining and camper conversion Q's. The super duper ply you want is Vohringer. Transfer to plywood, cut with jigsaw and you are done. Shogun Total War Warlord Edition Key Code. Find great deals on eBay for. Find great deals on eBay for vw transporter ply and vw transporter ply. Ply racking vw transporter ply lining vw. VW TEMPLATES, MADE FROM EXTERIOR GRADE PLY. Job Interview Online Practice Tests. Get Prepared For Any Interviewin only 3. New listing VW T4 Transporter SWB Camper / Day Van Interior 9mm Floor Ply Lining Kit. The other problem is cutting the templates out. VAN ACCESSORIES >Ply Lining Kits For Vans >VOLKSWAGEN VAN PLY LINING KITS >VOLKSWAGEN TRANSPORTER T4 PLY LINING.

You might want to consider fitting deadlocks on the cargo doors. Bulkheads between the cab and cargo area can also increase security, as well as provide wall storage. This van will eventually get a limo tint, and an internal security cage on the rear tail lift—bricks can open windows!

Everything in the cargo area is subject to shake, rattle, and roll. Tools and toolboxes must be secured so they don’t fall out. Simplicity is always the key. There is nothing more annoying than a squeak you can’t locate. The design and build should take these matters into account.

Ply Lining Kits: A No Brainer. I replaced the wheel arch covers with 3/4-ply. A ply bed in the van reduces drumming and provides a fixing surface—something solid to which other components can be secured. Ply lining to the walls protects the panels from being dented from the inside while also providing another fixing surface.

Re-sprays are expensive; ply lining kits are cheap. It’s a no-brainer.

This van came lined, so my first job was to replace the wheel arch covers with 3/4-ply to take weight, and to act as a fixing surface. I’d recommend rebuilding the wheel arch covers in smaller vans with 1x and 1/2-in. Plywood to improve strength. Ply-lined sides make locating the side ribs for fixing points more difficult. Roof ribs are far more useful.

Ply sides are fixed with self-tappers, so they won’t take any weight on their own. Adhesive/sealants like Sika EBT (an elastic polyurethane adhesive/sealant similar to DAP Polyurethane) are the best choice when incorporating ply linings as a monolithic part of the racking.

They also significantly increase the load-bearing capacity, and they take paint if you want to spray the racking. Don’t use silicone as a cheap alternative—the joints will fail after a couple of years of constant shaking in a van. Tools Dictate Layout Long, relatively delicate tools are the greatest challenge for racking layout, since they have to be carried flat. If you plan carefully, you can also build slots for door-hanging levels.

Long saw tracks are another matter—they can only be stored down low or high up, and they’ll need protection (see photo, right). The size and weight of chop saws and portable bench saws means they’ll want to sit on the bed, against the bulkhead. This is also the best place in an emergency stop. Plus, the sliding side door will make for easy access. Other heavier items, like dust extractors or portable thickness planers and compressors, are compact in size and easier to lift. You can be more flexible in their placement.

To avoid stressing your spine, consider positioning them so that you can lift them in and out without bending forward or twisting sideways at the same time you’re lifting. Wormdrives, heavy sidewinders, and transformers should also be placed with careful attention to your back. Today, the bulk of carpenters’ tools come in boxes—and good boxes, too. The more regular the box sizes, the more compact your racking can be. The remaining space is for everything else. Measure the Van The van you have may be the right size for the work you do, but before building any racks, measure it carefully.