DIY Aluminum Rock-n-Roll bed Part 1 // Cutting & Joining t-slot Extruded Aluminum

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Want to DIY your own rock-n-roll bed? Or build your van interior structure? Or build pretty much anything? Watch as I explain how I use 80/20 extruded aluminum to fabricate a rock-n-roll bed that not only converts to seat 4 (including 2 rear facing rumble-seat style seats). This material is like Mechano but on steroids. You can literally create anything, with basic wood working tools - although I'd recommend renting or buying a chop saw with a good blade because it will make your cuts look much nicer.

My Shopping & Gear List: https://gotmountains.ca/my-gear-list/
Van 2.0 build playlist: https://www.youtube.com/playlist?list=PLhdXnS65QjoHQfkaMu7hzBaWcdigHmKas

As promised in the video, here are some links about 80/20. I used the 10 series (1"), but would likely use the 20 series next time (20mm) as it was smaller, cheaper, and probably strong enough for what I needed. Chinese manufacturers don't make fasteners for the Imperial profiles, but I found that the 20 Series fasteners were close enough to work perfectly with the 10 Series profile. (NOTE: 10 (1") and 15 (1.5") series are Imperial, and all the rest are metric)

Inexpensive Fasteners on AliExpress:
DROP IN T-NUTS (finicky, but can be placed in a closed t-slot): https://www.aliexpress.com/item/32847391903.html
SLIDE IN T-NUTS (more solid/easier to use, but must slide in an open end): https://www.aliexpress.com/item/32890436184.html
CORNER BRACKETS (I used the 2028 size): https://www.aliexpress.com/item/33041248529.html
END SPRING FASTENER (used with an end tap, shown in upcoming video, stay tuned!): https://www.aliexpress.com/item/32869815497.html
HINGES (shown in upcoming video, stay tuned!): https://www.aliexpress.com/item/33026244264.html

WARNING!!! Stay away from these: https://www.aliexpress.com/item/32820525937.html (While they may look cool and seem to be easy to use, don't get sucked in. They are junk, have very little structural integrity, and seemed to come loose with very little movement in the structure)

For bolts, I was able to find everything I needed for a great price locally (called Edmonton Nut and Bolt). Buy everything by 50 or 100, you'll regret having to make another trip or wait 4 weeks for an order to come in from China! My only advice when buying bolts: make sure you can properly torque the bolts without them touching the bottom of the t-slot. There is about 2-3mm play between a bolt that is too short (and therefore a PITA) and too long (making it touch the bottom before the t-nut is properly torqued).

I also started with black steel bolts, but would recommend stainless steel so it doesn't react with the aluminum. For most of the bolts I used a Socket Head, but eventually switched to a Cap Head EXCEPT where I used an end tap with the end spring fastener (video to come).

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