Build a board rack for your van…
Tools, materials, and a few thoughts that may help…
A basic pencil/paper design with a few rough measurements are essential. You can calculate the materials needed so waste is kept to a minimum.
Be mindful of the space you have inside the van, and the fact you will need to see out the right side and rear windows.
1 1/2 inch ABS (black) pipe and fittings are strong and the least expensive way to go. 1 1/4 inch pipe and wooden dowels, whatever, can be incorporated into the mix but for the most part the size and cost will increase substantially. Be sure to use the ABS glue or screws to join and remove sections for easy removal from the van. There are 45-degree Hub Elbows for increasing or decreasing width as needed, see below.
A mitre saw or home made pipe cutting jig (pictured below) and versatile plastic box horses will help ensure accurate, flat, 90 degree cuts and a rigid structure to control and safely cut the pipe. Wear good quality safety glasses as the plastic bits do fly about.
The build should pretty much remain unglued until there’s a certainty the rack is workable. Small screws can secure the joints/build (if needed.) If the rack is to be moved into your basement (off season) it needs to be easily detachable (with fasteners/hardware) into two halves to get it through the doors and in and out of the van as well (see pic below)…
There are a large number of 1 1/2 inch couplers that can pretty much achieve whatever you want to do. Like many home made projects the first build will be a learning experience. Plastic pipe can be rearranged and modified as needs present. Mistakes can be fixed.
By the time you have made, modified, and lived with one rack for a few years the second build will be near perfect.
Plan with a secure floor & board rack attachment within your van. You don’t want this thing or your gear flying about the van when you need to stop fast or corner hard, get to the beach on a windy day, or back home, when you’re late for dinner.
I’d be happy to discuss the build with you, please email, call, or knock on the van window. This is my fourth build including a few dozen major/minor modifications as needed along the way since the first rack built in the mid/late 1980s. I can’t begin to include the many incorporated good and bad ideas that have unfolded into different racks over the years. The first pic below does not show the mast slings, 85L board securing, rack/van securing clamps,and more, etc. etc…
It’s one of those fail your way to success ventures that quite simply improves the take out, use, and consistent replacing/organization of your gear.
a. Use round head screws 2 & 3 Robertson, or a countersunk, recessed flat head if needed (stainless preferred).
b. Use a mitre box/mitre saw, power drill, impact drive screwdriver, assorted box and open ended wrenches for other needed attachments.
Go to the local hardware store and look through the many black pipe fittings (Plumbing section) available but remember to try to keep it simple. Electrician tape, Gorilla tape, adhesive backed weather strip moulding, pipe insulation, bungees, are all other options to consider to cushion boards etc. etc…
Tuh dah…
A test set up out side the van for possible flaw correction.
A rough plan on paper.
A jig to cut ABS pipe cleanly at 90 degrees.
Make 2 halves for easy put in and take out. Secure with #2 or #3 Robertson screws.
