Our first true carpentry project on the van was building our bed platform. We opted for an elevated bed platform that was designed with the intent to keep 4 bikes below it. Slap an 8″ memory foam mattress on and you’re living the life of luxury compared to the many nights backpacking and sleeping on thin sleeping pads.

Material, Tools, Cost & Labor

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[ebs_toggle active=”active” ocicon=”true” title=”Parts & Material” icon=”fa-gears” icontype=”fa” iconcolor=”#ffffff”]• 9 – 2″ x 4″ Boards
• 2 – 3/4” x 4’ x 8’ Maple Hardwood Plywood
• 2 1/2″ Wood Screws – http://amzn.to/2E6Hseo
• 2.5″ Hex Bolts (1/4-20 Thread) – http://amzn.to/2sbfNn3
• 1/4-20 Stainless Steel Fender Washers – http://amzn.to/2GW6gmW
• 1/4-20 Rivnuts – http://amzn.to/2nPq17d
• Kreg Pocket Hole Screws – http://amzn.to/2C1Lb6V
• Memory Foam Mattress – http://amzn.to/2AbNOG8
• Scrap cardboard (for template making)
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[ebs_toggle active=”active” ocicon=”true” title=”Tools” icon=”fa-wrench” icontype=”fa” iconcolor=”#ffffff”]• Jig Saw – http://amzn.to/2G5xebK
• Circular Saw (Optional) – http://amzn.to/2D9LFsf
• Kreg Pocket Screw Jig – http://amzn.to/2GSiIEi
• Rivnut Gun – http://amzn.to/2nPDxrw
• Carpenters Square – http://amzn.to/2G3h2I1
• Clamps – http://amzn.to/2FpejYD
• Tape Measure
• Pencil
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[ebs_toggle active=”active” ocicon=”true” title=”Cost & Labor” icon=”fa-clock-o” icontype=”fa” iconcolor=”#ffffff”]Total Project Cost: $XX
Installation Time: 7 Hours[/ebs_toggle]
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Process

Step 1: Framing the Bed Platform

To frame the bed platform we mounted our mountain bikes to our sub-floor and measured the minimum height needed for adequate clearance. We then added 2″ to account for the future bike drawer thickness and final vinyl flooring thickness. This ended up at 38″ from floor to the bottom of the bed platform.

This gave us the height of the vertical 2″x4″ columns for the platform. We cut the front and rear supports at the measured height with a notch for the horizontal 2″x4″ supports. This allowed for screws to be driven from the side as well as a pocket screw from below.

Once the front and rear columns were installed I used a 4 foot t-square to run a straight line across the two columns. Then we measured the height from the wheel well to the level line to create the to center columns. We installed rivnuts in the factory holes on the inner van walls. We could then bolt the 2×4 columns to the van walls but ensured the weight was resting on the sub-floor. Each column has between 2-4 bolts holding it to the wall.

We moved on to the horizontal supports next. These are simple 2″x4″ boards ran from side to side in the van. Measure the width, cut and install. Repeat. Knowing that we would use 2 sheets of plywood on the platform, with the seam running down the middle, we cut and installed braces between the horizontal supports. This would give proper support for the seam of the plywood platform.

Step 2: Installing the Platform

We are using a full size mattress sideways in the van. To hold it we used two sheets of 3/4” x 4’ x 8’ maple hardwood plywood as the platform. We used a piece of cardboard to trace out a template of the bed platform. Specifically around the rear corners and back doors.

We wanted a close fit to the rear door to create a shelf on the backside of the bed for a place to stash phones, books, etc while in bed. After spending a fair amount of time creating a good fitting template, we traced it on to the plywood to be cut out by a jigsaw. We could flip the cut board to create the opposite side with the exception of how the board fit around the center door frames since they are slightly different on each rear door.

Ultimately the boards fit well using this approach. We secured them to the platform with 1-1/2″ exterior screws placed every 8″ along the horizontal supports. To help with ventilating the memory foam mattress we drilled a 1″ hole in the platform approximately every 12 inches.

Step 3: Mattress Trim / Barriers

Coming soon…

Our Experience

Installation Process

Coming soon…

Performance

The bed is comfortable and allows us to sit up (we’re 5’6″ and shorter) which is nice. It’s an incredibly sturdy build with no noticeable wobble, sway or flex. Driving down the road there isn’t any squeaking or noise to speak of either which was a major goal of the build from the beginning.

In Retrospect

After using the bed on a couple of overnight trips we can say that the mattress was a very good choice and super comfy. Also the height of the bed has been fine as well. I think we would make the area for the mattress an inch wider. I originally measured the width of the width bed without the idea of a board in the rear to prevent movement and the memory foam mattress expanded just a tad more than the listed specs. However, the mattress fits tight and stays in place so I can’t complain. Also the front board, a 1″ x 6″ pine board, is too short to provide confident holding area for the front mattress edge. With 4 inches attached to the frame and only 2 inches sticking up in front of the mattress it doesn’t seem secure enough. Swapping to a 1′ x 8″ board will provide 4″ of lip for the mattress.

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