Sorry for slow replies gentlemen. I don't get here much these days.
First of all I had Van Specialties (.com) do my interior in the Portland Or area.
My idea, their build.
The idea had to be worthy enough for them to take it on. And a fine job they did.
The top horizontal edge is structural as is horizontal mid height, thus D-rings & Mac track at each.
I do not know their fastening method! Speak with Rob, their/my sales person & he may enlighten...
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I have the same questions! How necessary are the aluminum cross-bars? If you can sleep one with half the bed down with just the legs, why the full length cross-bars? What is the bed made out of, 3/4" plywood covered in carpet? Thanks!
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The cross bars are the original design & the folding legs after thought - kind of redundant.
But... with the bed down & cross members used I have full underneath room for storage while sleeping.
I may (and do) have to move gear to drop the legs when not using the cross members.
Yes I can sleep on either half at a time. For solo camping this is killer as I have mucho room to sit up, stand up, dress etc.
The bed is either 5/8" or 3/4" plywood, I don't remember which. Using the cross members allows for lighter spec plywood... The bed height is just high enough for the plastic tubs to fit underneath.
Carpeted yes, matching the rest.
We use a full size chambered air mattress which gives room on each side for nightime necessities and my carbine.
Brainstorm your build gentlemen!
I have a Murphy bed idea for someone trying to do something different. Full length available for gear and a dining table/seats built in also.
Thanks for the questions.