Drill Jig for 80/20 Bed Frame Vertical Legs

We designed and 3D printed this Drill Jig, to precisely align the legs with the existing holes in the van (could be useful to attach panels or such in the future), and to locate the legs flush with the van’s surface:

Index the drill jig into the two existing holes, then use a center punch to mark the center of the holes:

Start by piloting the holes with a 1/8″ drill bit, then use a step drill bit to open the holes to their final diameter of 7/16” (using a normal drill bit will deform the thin sheet metal):

Note: be careful not to bottom-out when drilling the holes for the front legs (there is another sheet metal below).

Deburr, smooth, and paint the edges. Install a 5/16-18 rivet nut in each hole:

Note: stack washers under the rivet nut, as required, to prevent bottoming out during the installation (for front legs only). This ensures the tool’s shaft doesn’t protrude past the rivet nut.

Install 3M protective film between the rivet nuts, where the surface mate with the vertical legs:

Install the vertical legs to the van using corner brackets, ball-spring-t-nuts (I always use these on vertical frames, because they stay in place), 5/16-18 x 5/8″ screws (in leg), and 5/16-18 x 3/4″ screws (in van):

Note: You can trim the corner brackets so that they are flush with the surface (this could be useful if you install walls in the future!).