The Happijac Bed Lift system is a specialized mechanical solution designed to optimize interior space in van conversions and recreational vehicles (RVs). By allowing the bed to rise and lower on command, it frees up the floor area for other functions such as seating or storage during the day. This article provides a detailed, step-by-step installation guide based on available technical information from Happijac dealers and user reports, offering insights into the process and considerations necessary for successful installation.
Installation Overview
The Happijac Bed Lift system is not sold directly by the manufacturer but must be purchased through authorized dealers. As of the latest available information, one such dealer offers personalized guidance, correct sizing, and international shipping to accommodate a variety of build scenarios. This approach is particularly useful given the limited availability of comprehensive installation resources online and the complexity involved in ensuring proper alignment and structural integrity.
The installation process is divided into five key stages: preparation and wall alignment, track installation, motor and drive shaft connection, bed frame construction, and final checks and adjustments. Each stage requires careful attention to detail to ensure the system operates smoothly and safely.
Stage 1: Preparation and Wall Alignment
Before beginning the physical installation, it is critical to ensure that the walls of the van or RV are perfectly square. This step is foundational because any misalignment can lead to uneven movement of the bed or structural stress on the lift system. The documentation emphasizes that measurements must be consistent from top to bottom and across the space, with an allowable error of less than 1/4 inch.
Key considerations during this phase include:
- Squareness check: Measure opposing distances (e.g., front-to-back on the driver’s side and passenger’s side, as well as diagonal measurements from front-top to bottom-back and vice versa) to confirm the walls are aligned.
- Repetition of measurements: The documentation recommends measuring everything at least three times to minimize the risk of human error.
Failure to align the walls correctly can compromise the functionality of the lift system and may lead to mechanical issues during operation.
Stage 2: Track Installation
The track forms the backbone of the Happijac Bed Lift system, guiding the bed as it moves vertically. The installation process involves mounting the tracks as high as possible to maximize headroom, which is particularly important in compact living spaces like van conversions. The tracks are typically mounted to the ceiling and floor, with the bed frame running between them.
Key steps during track installation include:
- Mounting height: The tracks should be mounted as high as possible to optimize headroom. In some cases, slits can be cut into the ceiling to accommodate the top notches of the tracks.
- Temporary support: To position the tracks correctly, a stack of scrap wood should be placed under each leg to hold the tracks in place while screws are being inserted.
- Centering the tracks: It is essential to measure from the centerline of the vehicle to ensure the tracks are exactly centered. Vertical alignment is also critical—ensure that the legs are at 90 degrees and do not converge or diverge as they extend downward.
- Screwing in the tracks: Begin by screwing in two screws at the top and bottom of each leg to hold the track in place. Once the alignment is confirmed, all remaining screw holes can be filled in.
The documentation also notes that it is important to measure and confirm the vertical alignment of the legs before fully securing the tracks. This step ensures that the bed will move smoothly and without resistance.
Stage 3: Motor and Drive Shaft Connection
The motor and drive shaft are responsible for powering the movement of the bed. Connecting these components requires careful attention to detail to ensure the system operates efficiently and safely.
While the provided documentation does not include detailed specifications for the motor itself, it emphasizes the importance of proper alignment and tension in the drive shaft. The drive shaft must be securely connected to the motor and the bed frame to ensure synchronized movement. Any slack or misalignment can result in uneven lifting or potential mechanical failure.
Key considerations include:
- Secure connections: Ensure that all bolts and joints are tightened to the manufacturer's specifications.
- Tension checks: After installation, it is recommended to manually test the movement of the bed to ensure the drive shaft is not over-tight or loose.
This phase is critical for ensuring the system operates smoothly and without unnecessary wear on the mechanical components.
Stage 4: Bed Frame Construction
The bed frame is a custom-built component of the Happijac system and is constructed using aluminum channels, cross beams, and plywood. This modular design allows for flexibility in size and shape, accommodating a wide range of van and RV builds.
The documentation outlines the following key steps in bed frame construction:
- Material selection: Use aluminum channels and cross beams for the frame structure. These materials provide the necessary strength and durability while remaining lightweight.
- Plywood platform: A plywood base is added to create a flat and stable surface for the mattress.
- Assembly: The aluminum channels and cross beams are assembled to form the skeleton of the bed frame. Once the structure is complete, the plywood is attached to create the sleeping surface.
It is important to ensure that the bed frame is built to the exact dimensions required for the van or RV to fit within the tracks and allow for smooth vertical movement. Any discrepancies in size can lead to binding or misalignment during operation.
Stage 5: Final Checks and Adjustments
After the physical installation of the system is complete, a series of final checks and adjustments should be performed to ensure the system functions as intended. These steps are essential for identifying and resolving any issues that may have developed during the installation process.
Key tasks during this phase include:
- Chain tension check: The documentation notes that in some cases, the horizontal chains may be loose and may not have a tension adjustment bolt. If this occurs, weather stripping can be added to the bottom lip of the metal to prevent the chain from making noise when it moves.
- Lighting installation: If recessed or ambient lighting is desired, it should be installed at this stage. All wiring should be combined into a single wire strand and left with enough slack to accommodate the full range of motion of the bed.
- Functional testing: The bed should be manually raised and lowered to ensure smooth operation. Any resistance or unusual noise should be investigated and corrected.
This final stage is crucial for verifying that the system is working as intended and that any potential issues are addressed before regular use.
Considerations for Buyers and Installers
The documentation provides several key considerations for potential buyers and installers of the Happijac Bed Lift system:
- Availability and purchasing: The system is not available for direct purchase and must be obtained through an authorized dealer. This can be a challenge for buyers who are not familiar with the distribution process.
- Installation complexity: While the Happijac system is marketed as a user-friendly solution, the installation process requires a moderate level of technical skill and attention to detail. The documentation suggests that one-on-one support from an experienced dealer can be invaluable.
- Headroom trade-off: Although the system increases usable floor space, it also reduces available headroom. Buyers must calculate the remaining headroom (ceiling height minus the thickness of the bed frame and mattress) to ensure it is comfortable for their needs.
- Customization and support: The documentation emphasizes that the dealer offers personalized guidance and support, which is particularly useful given the limited availability of detailed installation resources online.
Conclusion
The Happijac Bed Lift system is a versatile solution for maximizing space in van conversions and RVs. Its installation requires careful planning and attention to detail, particularly in ensuring wall alignment, track positioning, and bed frame construction. While the system offers significant benefits in terms of space optimization, it also requires a trade-off in headroom and a moderate level of technical expertise for installation.
For those considering this system, it is recommended to work closely with an authorized dealer to ensure correct sizing, installation, and ongoing support. The documentation highlights the importance of precise measurements and thorough testing to ensure the system operates smoothly and safely over time.