I switched it up in this build and built the entire structure out of 80/20 aluminum extrusions! I'm really happy I did because it is really strong and doesn't squeak or rattle AT ALL while driving. Not to mention, it's pretty lightweight relative to its strength.
80/20 Extrusions (save on shipping by ordering 5+): https://amzn.to/3LGCrdm
80/20 Corner Brackets: https://amzn.to/386NJE5
80/20 Roll In T-nuts: https://amzn.to/3E6Xgvm
80/20 Bolts: https://amzn.to/3b24MZT
Dewalt Miter Saw (w/XPS laser): https://amzn.to/3hAuJ4h
Dewalt Miter Saw Stand: https://amzn.to/388bIDd
Aluminum Cutting Blade: https://amzn.to/351YeGW
Hole Deburring Tool: https://amzn.to/385YMxy
Plusnuts: https://amzn.to/3b250jH
Plusnut Installation Tool: https://amzn.to/2LjvL8r
Closed Cell Foam Padding: https://amzn.to/2X834xS
Drill Press: https://amzn.to/38VSgbN
Favorite Drill Bits: https://amzn.to/2LgejBI
Timestamps:
0:00 - 1:07 Overview
1:07 - 2:00 The First Step (Planning)
2:00 - 3:05 What You'll Need (4 parts)
3:05 - 3:35 Floor Tape Mockup
3:35 - 4:00 Tools For Cutting 80/20
4:00 - 5:30 First Day's Progress
5:30 - 7:00 Passenger Side Completed
7:00 - 7:45 Plans For Driver's Side
7:45 - 8:45 Roll-In T Nuts (SO NICE!)
8:45 - 9:15 Driver Side Progress
9:15 - 10:10 I Made A Mistake
10:10 - 11:00 Tip For Heavy Battery Compartment
11:00 - 11:30 Update on Progress So Far
11:30 - 13:30 Methods For Securing 80/20 to The Van
13:30 - 15:55 Mounting Method #1: Plusnuts
15:55 - 18:50 Mounting Method #2: Carriage Bolts & Spacers
18:50 - 19:50 Update After Finishing Mounting
19:50 - 21:20 Pain Of Non-80/20 Aspects
21:20 - 25:50 EVERY SINGLE Mounting Point & Method I Used
25:50 - 28:08 Summary & Outro