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12-31-2008, 11:46 PM
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#1
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Member
Join Date: Dec 2008
Location: Oregon
Posts: 53
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DIY Ladder Mod
I really wanted a ladder for the side of my new to me Quadvan conversion, but I balked at the price of a professionally manufactured one, so I combined a bunch scraps in the shop with $20 worth of EMT, $5 worth of SS hardware, and a $5 can of Duplicolor truck bed liner. 30 bucks and a few hours of fabrication got me a serviceable prototype side ladder. It's probably not as light as the Aluminess version, but certainly durable and very cheap.
The brackets are a little crude and a couple of the bends could have been a bit cleaner, but as a proto based only on shapes that I've seen in pictures online, that's to be expected. If I make another one it'll be a lot cleaner.
If you've got a welder and grinder, and are looking for a good weekend project, you'll be money ahead even if you have to buy the EMT bender, a notcher, conduit, and some steel.
I'll try to get a better profile picture tomorrow to show the final product.. A few more pictures of the project are in my album.
Happy New Year!
__________________
2003 Ford E350 PSD, EB Cargo, Quadvan 4x4
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01-01-2009, 11:23 AM
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#2
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Senior Member
Join Date: Oct 2007
Location: SoCal
Posts: 1,071
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Very nice. Where were you two months ago when we ordered 10 of them?
Looks really nice!
steve
__________________
'05 Ford V-10 4x4 SMB "50" White
'00 Jeep Cherokee 4x4 Highly Modified
'04 Jeep Grand Cherokee- wife won't let me modify it. :-(
Does anyone really read this stuff other than surfgeek?
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01-01-2009, 01:13 PM
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#3
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Senior Member
Join Date: Apr 2007
Location: Santa Barbara, CA
Posts: 1,841
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Nice work!
Those of us that can fabricate and machine surely understand what this project requires. Other may simply stare in awe!
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01-01-2009, 01:34 PM
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#4
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Senior Member
Join Date: Aug 2008
Location: Port Townsend, WA
Posts: 206
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Yep, that's me, standing in awe! Well actually, as you see, not exactly standing..
__________________
1993 E350 SMB, 15M, 84k miles - a cheap date
2006 Toyota Prius because we like clean air
2002 Honda Odyssey - can haul lots of stuff
1972 Mercedes 350SL with 4.5l V-8, just because
Wag more, Bark less, Play well with others.
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01-02-2009, 07:27 AM
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#5
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Senior Member
Join Date: Aug 2008
Location: Thousand Oaks, CA
Posts: 296
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Excellent!
Good idea and nice job.
__________________
07 E350, Custom and Lifted
08 Harley Davidson Street Glide
09 KTM EXC 530
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01-02-2009, 10:07 AM
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#6
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Senior Member
Join Date: Jul 2008
Location: Forest Falls CA
Posts: 876
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Looks good!
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01-02-2009, 10:04 PM
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#7
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Member
Join Date: Dec 2008
Location: Oregon
Posts: 53
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Quote:
Originally Posted by cellularSTEVE
Very nice. Where were you two months ago when we ordered 10 of them?
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I just found the forum a few weeks ago, I think shortly after you had taken delivery of your ladders. I remember reading the posts on that order and feeling bummed for being too late to get in on that deal.
I just picked up my van ten days ago, so I actually started working on the ladder prior to delivery. I used my RB cargo as a template which worked out fine. Given the low tech approach, the ladder turned out great. Time will tell as far as durability goes. I'm sure structurally it'll be rock solid, but I haven't used the Duplicolor spray-on liner before, so it may be a bust. I may have to take the ladder in and get it sandblasted and powdercoated at some point.
Here's a better image of the ladder from the side:
And another up close:
This project really isn't above the average welder. I had never bent emt before I started on this. The conduit benders are really easy to use. I'm sure you could rent a bender for cheap too. The only other tip I would suggest is removing the galvanizing around the area to be welded to keep your joints clean. I just touched up the areas with a coarse wire wheel, and seemed to work pretty well.
Before I tacked the pieces together I made a template of the left beam so I could replicate the shape again. It has reference marks for positioning the bender and approximate degrees for each bend. If you think you want to tackle this project, I could probably digitize the template and get it to you via email.
Cheers,
Sam
PS
The sliding door is cleaner than the rest of the van because I took it off my RB cargo a couple of days ago. I wanted to have side and rear windows in the 4x4, so I just swapped the doors over from my old E250. The Quadvan came sans glass in the rear and a bare cargo, but I hope to have subfloor, all weather flooring, two captains chairs and a bench installed later this week.
__________________
2003 Ford E350 PSD, EB Cargo, Quadvan 4x4
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01-04-2009, 05:35 PM
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#8
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Senior Member
Join Date: Jul 2008
Location: Fruit Heights, Utah
Posts: 119
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Killer job!
I'm installing my ladder, I got one on the group buy, but yours looks incredible and I'm sure is just as strong, and hay $40 and some time is better then $400 any day!
I'm also trying to build many different things for my van, (our vans look a lot a like) I just got mine as well, Quigley 4x4 with the sliding door as well (I really wanted the barn doors, but oh well), I really would appreciate any assistance, tips, etc. on any other project you decide to take on, because a lot of this will be a first for me as well.
Again, killer job, keep up the good work,
__________________
Cheers,
Jamie
2006 E350 Quigley 4x4, building the conversion with the gracious help from the people on this awesome forum!
I'll try & post all of our progress on our family dream, when we have some.....
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01-15-2009, 08:07 PM
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#9
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Senior Member
Join Date: Jan 2009
Posts: 1,220
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What diameter EMT did you use?
__________________
Len & Joanne
The Green TARDIS
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01-16-2009, 06:24 PM
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#10
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Member
Join Date: Dec 2008
Location: Oregon
Posts: 53
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1" EMT. I think it was about $10 a stick at the local hardware store, so I'm guessing you could get it a bit cheaper at a big box.
__________________
2003 Ford E350 PSD, EB Cargo, Quadvan 4x4
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