2024 MAN TGE L4H3 4x4 build

[Lebowski]

I have a build thread on camperforum.nl and I will post some updates here to keep everybody happy. My introduction thread can be found here.

My van is a 2024 'Next Level' facelift model with a 4x4 system, in length 4 and height 3, or L4H3 in short. I bought it new as I found it difficult to find a high quality used van with the right features, them being the upfitters module under the drivers seat (in your case the passenger seat) as I have an LHD vehicle and a have a diff lock and suspension seats for comfort.

The final form of the van will be a mix of LCV and campervan as I need to be able to move goods too. Because of this I will create a build that is flexible and light in weight and I will retain the floor fixating points. These vans are heavy and mine weighs according to the COC 2640kg. I went to the skip and weighed it and was told 2650kg, but that;s probably my gut being a little heavier than the standard 75kg added as the driver weight.

This means according to my calculations that the heaviest dry weight I can be is 3167kg to be able to take enough people, luggage and water AND stay under 3500kg.

In The Netherlands uprating means you also need a C1 licence limiting the demographic that is willing to purchase my van when I move to the next one. Also you can only drive 90 km/h max and pay higher tolls on the EU-roads. And the wife needs a C1 licence too in case of emergencies as legally she won't be allowed to drive a C1 vehicle with a B licence.

I have already added Schnierle seats in the back and they can be taken out in 10 seconds resulting in a huge cargo space.
Then Dometic windows were ordered and one was placed inn the vehicle and one was lost in transit.
Now the van is parked at CJL Leisure to fit flares as I want to sleep sideways to maximize the inner space.


The rails have been placed in such a way that you can put one Euronorm crate between them and use the C-track eyelets to secure it with a bungee cord or a ratchet strap. The intention is to not have ONE part of wood in my vehicle, especially on the floor.

 

[Lebowski]

I picked up the van this morning at 1145 and the flares are on the vehicle now, I'm happy as I can proceed to insulate this part too, that should make quite a difference in noise transmission but also creation.

 

[Lebowski]

@rod_vw when you have seat cables available for the swivel seats I'd like to buy a set for two massage suspension seats. Don't know how many pins are populated but my guess is all of them.

I read about your venture and ice purchased a set of Audrio swivels and found that the cables are too short to swivel 180 degrees.

 

[rod_vw]

@rod_vw when you have seat cables available for the swivel seats I'd like to buy a set for two massage suspension seats. Don't know how many pins are populated but my guess is all of them.

I read about your venture and ice purchased a set of Audrio swivels and found that the cables are too short to swivel 180 degrees.

Hi @Lebowski , is it the red 17 way connectors that you have under those seats? If so I am hoping that the ones that I am developing for the twin seat swivel will have all 17 wires populated with the same wire cross section as shown on genuine wiring diagrams. Time will tell how this all works out and what length extension loom would be needed for your type of seat. Please keep in contact but remember that I'm on holiday from the end of this week until the first week of October, six weeks in Europe with the TGE .

 

[Lebowski]

No hurry and I'll make pictures when I get the chance.

 

[Lebowski]

I've got to pick up some goods (wheel carrier + luggage rack) at Wheeliams in a couple of days but haven't heard anything from them, on their website is just an administrative address, a residential home. Does anyone have their phone number and workshop address?

 

[Lebowski]

Never mind: I did get a reply but unfortunately due to bad internet reception email delivery was slower than usual

 

[Lebowski]

Yesterday in Alnwick; was parked at the local Lidl when a fellow Crafter van parked next to me. Maybe he's also on the forum?
We went to Alnwick Castle to see the Harry Potter sights and undergo broomstick flying training, the kids had fun and so did we!

There was a troupe of four men doing comedy with kids called the Silly History Boys and they also have a podcast, started listening to them and they rock!


Today: Picked up the goods at Wheeliams' workshop in Scarborough and chucked them in the van, will send them to powder coaters when at home but have to decide on the colour:
1: black, not very original
2: a near identical colour to Indium Grey to hide the parts from plain sight.

 

[Lebowski]

Things are starting to come together more and more. The custom-made roof rack has been delivered to the designer, Jeroen, also known as VNK on the Dutch forum.

Jeroen designed the roof rack in such a way that there’s enough height to fully open two Maxxfan Domes under the panels, lights can be mounted on the sides and back, and there’s space for a keder rail on both sides. An awning of this length weighs about 35 kilos, which is simply too heavy and not flexible, so we opted for a fabric solution that weighs just a few kilos. You’ll need a telescopic ladder for it, but that’s handy to have anyway.

The roof rack is designed for the Craig Solar solar panels I bought in England last month. They measure 147 x 67 cm, and four of them fit in a row, giving me 800Wp of power generation on my roof soon. Behind them, there will be a Maxxfan Deluxe Compact in the color smoke. To the left, there’s a streamlined aluminum box for a kinetic tow rope and some other stuff, and to the right, two recovery boards in an identical box with a Starlink on top. The boxes will be slightly higher than a closed Maxxfan, so the plastic cover isn’t the highest point on the roof, and the boxes can absorb any impact from branches.

At the back, there will be separately switchable floodlights for reversing in the dark, and a rearview dashcam for evidence against reckless drivers on the road. Of course, there will also be a dashcam behind the windshield, but that’s not the topic right now.

Another huge advantage of this roof rack is that it weighs only 14.7 kilos and has a spoiler to minimize air resistance. There’s no lighter roof rack available for purchase.

In two weeks, I’ll pick up the parts and bring them, along with the Wheeliams products, to the powder coater the following week to have them coated in RAL7024 (Graphite Grey) dark grey. I’m counting on a few weeks for that as well, so installation won’t start before mid-October. After installation, the Maxxfan Domes will also be fitted into the roof, as then I’ll know for sure they won’t be placed where a solar panel mount is.

Price: € depends on the daily aluminum prices, which fluctuate quite a bit. My roof rack is slightly cheaper than future racks since it’s a prototype.

After this rack is done, we’ll work on a few more products, namely two boxes for the roof and a battery box under the vehicle. That’s going to be a very interesting project too, which I won’t say anything about yet, but it’s going to be VERY cool!

@everyone with a Crafter / TGE L3 or L4: this roof rack was made for the L4 and can be ordered from Jeroen, also for the L3. He’ll make a shorter version for that.

 

[Huxwar]

Things are starting to come together more and more. The custom-made roof rack has been delivered to the designer, Jeroen, also known as VNK on the Dutch forum.

Jeroen designed the roof rack in such a way that there’s enough height to fully open two Maxxfan Domes under the panels, lights can be mounted on the sides and back, and there’s space for a keder rail on both sides. An awning of this length weighs about 35 kilos, which is simply too heavy and not flexible, so we opted for a fabric solution that weighs just a few kilos. You’ll need a telescopic ladder for it, but that’s handy to have anyway.

The roof rack is designed for the Craig Solar solar panels I bought in England last month. They measure 147 x 67 cm, and four of them fit in a row, giving me 800Wp of power generation on my roof soon. Behind them, there will be a Maxxfan Deluxe Compact in the color smoke. To the left, there’s a streamlined aluminum box for a kinetic tow rope and some other stuff, and to the right, two recovery boards in an identical box with a Starlink on top. The boxes will be slightly higher than a closed Maxxfan, so the plastic cover isn’t the highest point on the roof, and the boxes can absorb any impact from branches.

At the back, there will be separately switchable floodlights for reversing in the dark, and a rearview dashcam for evidence against reckless drivers on the road. Of course, there will also be a dashcam behind the windshield, but that’s not the topic right now.

Another huge advantage of this roof rack is that it weighs only 14.7 kilos and has a spoiler to minimize air resistance. There’s no lighter roof rack available for purchase.

In two weeks, I’ll pick up the parts and bring them, along with the Wheeliams products, to the powder coater the following week to have them coated in RAL7024 (Graphite Grey) dark grey. I’m counting on a few weeks for that as well, so installation won’t start before mid-October. After installation, the Maxxfan Domes will also be fitted into the roof, as then I’ll know for sure they won’t be placed where a solar panel mount is.

Price: € depends on the daily aluminum prices, which fluctuate quite a bit. My roof rack is slightly cheaper than future racks since it’s a prototype.

After this rack is done, we’ll work on a few more products, namely two boxes for the roof and a battery box under the vehicle. That’s going to be a very interesting project too, which I won’t say anything about yet, but it’s going to be VERY cool!

@everyone with a Crafter / TGE L3 or L4: this roof rack was made for the L4 and can be ordered from Jeroen, also for the L3. He’ll make a shorter version for that.

View attachment 1338

This sounds good! Will await pictures with interest @Lebowski