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BODY BUILD

Underfloor Storage And Outdoor Shower

By |November 28th, 2017|BODY BUILD, BUILD, PLUMBING|0 Comments

Back on it, finally. Have been away 4 times to Melbourne and Sydney in the last 5 weeks, a total of 3 weeks away and a few other things, so not much work on the van. Things have been slow, too busy with my commercial project. Earlier I continued working on the underfloor storage. Glued the walls in and the remaining baggage doors.

 

The larger compartments are done now. A few bits are left to do though. Next step was the compartment for the outdoor shower.

I prepared the inner wall with the installation of the mixer unit. It is a […]

Under Floor Storage

By |March 15th, 2017|BODY BUILD, BUILD|0 Comments

I mentioned in the previous post that I also started to do some body work again, and that would include my own body too :). Joke aside, I have fitted the floor for the storage boxes under the main floor. I use the cut-offs from the windows and baggage doors to do most of it, but it will not be enough. I have another alu honeycomb panel to do the rest. The panel is a 10mm with alu skin on one side and a vinyl(white) on the other which will be facing inside. These panels are lighter than the […]

Heating Installation Started

By |December 6th, 2016|BODY BUILD, BUILD, PLUMBING|0 Comments

Today I have started to place the heater outlets. The first is the one in the living area. It is a 4.5 kw Webasto 3 stage fan heater. Originally I only wanted convection heat, but I decided that we are using the fan forced heater for faster heat up. We have the floor heating for the “soft” heat if required.

In the morning I was at Masters and raided the PEX fittings. Nobody buys this stuff and they had pretty much left what I needed. I bought a few and some more, just in case.

I bought another couple […]

Hot Water Solar

By |December 3rd, 2016|BODY BUILD, BUILD, PLUMBING|0 Comments

After the last tarp was ripped to pieces by the winds I started to work on the roof. I had finished the hatches and also done the extractor fan and all the trim along the roof edge. Next on the list were the solar panels for the hot water.

I organised the fittings for the panels and the connections for the pex pipes. Above image shows the panels prepared to go on the roof .

The left panel with the inlet connection.

Above image shows the connection between the panels and the right side outlet. I allowed some space around the panels […]

On The Roof

By |November 23rd, 2016|BODY BUILD, BUILD|0 Comments

The second tarp, which was still hanging on a few threads, has finally given up and was shredded by the wind we had recently. I removed it completely and used the opportunity to work on the roof and on the edge. I installed edge trim on both sides, 6.5 m each piece, however it is not yet finished. A few bits are missing towards the front. Will do that in the next days before I put new tarps up. Will also give the front part of the roof a bit of a clean and also the top of the […]

Gutter

By |September 11th, 2016|BODY BUILD, BUILD|0 Comments

This is the front of the van after a few weeks of rain and not having a cover anymore. Lots of sticky stuff from the trees and dirt washed off the roof down the front. I should have installed some gutters a long time ago to let the water flow off to the side and not wash all the dirt onto the baggage doors. The little service door for the power inlets caught a lot of dirt and I want to keep the water away from it especially when power cords are connected.

I have plastic gutters, self adhesive, to […]

Bed Slide-out

By |June 8th, 2016|BODY BUILD, BUILD|0 Comments

Finally,
the last slide-out is in .. took 6 months since I am back from QLD. Time flies when you are busy.

I had the box and the opening prepared and yesterday my young mate came by to help me to lift it in.
It is not really heavy but a bit awkward with the long bed base. Would not trust any of my older mates
to handle it, so had to wait for the young bloke, however he has a sore wrist right now and I have torn
a ligament in the left elbow at the gym. Nevertheless we managed to get it […]

Another Milestone – The Right Side Is Closed

By |February 29th, 2016|BODY BUILD, BUILD|0 Comments

Everything in on the right side, slide-outs, windows and baggage and service doors.

Here is the image with numbered doors and below is the list of door purpose.

1 – Pull out garbage bins and bottle container
2 – Service opening for air filter of the positive pressure system
3 – Ventilation door for air condition compressor
4 – Air condition compressor main door
5 – Electric BBQ slide-out shelf
6 – Pass through storage for my surfboards and other longish items
7 – Wide door storage for kites, harnesses and life vests
8 – Wide door storage for kites
9 – Pass through storage for long items, like […]

Batteries Are In – Another Milestone

By |February 19th, 2016|BODY BUILD, BUILD, ELECTRIC|0 Comments

Another small task today was loading the batteries into their place in the van. I borrowed one of the fork lifts of my neighbour, which made it easy. Just lifted the batteries into the openings and pushed them onto the extra floor panel. This panel is positioned on top of the actual floor panel to distribute the weight over a larger area.

The batteries will be bolted down with large bolts through the floor and additional braces under the neck to make sure that they do not move a bit, especially not when an accident happens and […]

Living Area Slideout

By |February 19th, 2016|BODY BUILD, BUILD|0 Comments

Over the last 3 days, a few hours at the time, I have built the living area slide-out box and today with help from a mate I have fitted the slide-out to the body.

It is a lot quicker the second time around, since I new what to do with the slide-out mechanism. There were the plastic pins again in the mechanism, which I removed, and replaced with a rivet. The slide-out mechanism installs in less than 5 minutes per side. It is real easy and the mechanism is light, I still have to put the limit bolts in like […]

Trim and other detail

By |February 19th, 2016|BODY BUILD, BUILD|0 Comments

Over the last 10 days or so I have done a lot of detail work, which does not really look like a lot but it all takes time, and I still spent a fair bit of time with my commercial project and meetings.

The body moulding is finished on the passenger side and so is the trim around the awning recess and the front neck area.

The graphics are fixed on both sides. Just a simple strip – keeping it subtle. Enough hatches, windows and doors anyway. I am not a friend of these cheesy American graphics […]

Body Work

By |February 9th, 2016|BODY BUILD, BUILD|0 Comments

It is almost a week since I posted the last time. Not that I have not done anything, but I was again busy with other things. I moved servers again with a bunch of domains and sites including this because the new host I had was also unreliable, real pain. Finally I found a host that seem to work better, however I am still having a couple of issues with automated WordPress backup.

The work on the van was primarily outside. The vinyl around the bottom, alu trim on the edges, baggage doors, fitted the main entry door and a […]

Body Protection

By |February 2nd, 2016|BODY BUILD, BUILD|0 Comments

I have not posted for a few days. Lots of things to do including moving this and other websites to a new host server. Had enough of email problems with the old host, just not reliable enough, especially when you host sites for businesses relying on email for 99.9% of transactions.

Have installed some more vinyl film to the lower part of the outer body. It is a bit awkward to put on and I still have a few small blisters left, but not too bad, so I do not bother to get them all out at this stage, it […]

Slide Out Mechanism

By |January 26th, 2016|BODY BUILD|0 Comments

I had quite a bit of trouble with the slide-out mechanism on several levels. Here is a summary of my findings and what I did or going to do about it.

As described in previous posts my slide-out box is made differently than the average Lippert (Schwinteck) slide-out. All slide-outs are made of a box and then a frame is put around the outside and the inside of the box to cover the mechanisms and the gaps as well as sealing the wall in both positions. The frame on the outside is usually 100mm wide and is connected to the […]

Water Inlets

By |January 22nd, 2016|BODY BUILD, BUILD|0 Comments

First post since some time. Been busy with many things, mainly my commercial project, kiting and tennis, however I have done a few things to the van in the meantime. A lot of hours went into the testing of the slide-out mechanism. I will write about this in another post.

Above image shows the water inlets for fresh and drinking water behind a baggage door. I do not like the little plastic doors one usually finds on caravans as the water inlets. These are not very solid and when exposed to UV will eventually get yellow and brittle.

I do not want […]

Work Slide-Out Is In

By |January 13th, 2016|BODY BUILD, BUILD|0 Comments

Before I could insert the slide-out box into the opening, it had to be prepared. Plastic cups are fitted bottom left and right to keep any water out which may run in through the slide mechanism. It would me minimal, nevertheless the plastic piece prevents the water from running inside. Bottom and top width are cover with a wipe seal.

 

The wipe seal also has a bulb seal attached. The intent is to seal the top and bottom when the slide-out is in, however it is only top and bottom and not left and right. The left and right […]

Work Slide-Out Box

By |January 11th, 2016|BODY BUILD|0 Comments

This week we had several very hot days and as a result I did not do much outside. Office work and done some work on the work area slide-out early in the mornings.

The most level surface I have right now is the van itself. I decided to build the slide-out box for the work area inside the van because it would be the best place to get in nice and square.

The face panel was cut with the CNC router in QLD and I had already removed the glass and the foam from the rebate around the outside. Cutting the […]

Central Processor

Have fitted the touch screen. It is the wall to the left at the front entry. The fridge is behind that wall. There is not much cable from the processor to the display and the controller board. It is a LVDS display and I did not feel like extending those tiny, flimsy cables. I picked a height to allow the processor to be mounted above the fridge.

 

The images above show the rear of the display and the processor box. All the connections to the processor go into the right (rear) of the box. The processor is fan less […]

Fitting Baggage Doors

By |December 22nd, 2015|BODY BUILD|0 Comments

One of the points for me to build my own van was utilising space for storage better than what I have seen so far and also the quality of the finish. I don’t really like those plastic doors with these huge frames which get screwed onto the outer walls. With cladding this might be necessary to keep them attached, I guess you need some support underneath, but it is rather difficult to keep them tight without a huge amount of sealant.

A very bad example how to fit doors was my slide-on camper from the US. Ok it was cheap, […]

TV Lift

We will have a larger TV in the van on a lift in a box behind the dinner table. At the moment we will probably use one of our 40″ LEDs I have from a project. It has a glass front and a touch frame so I can use it as a touch screen for a pc as well not just as a TV. However we plan to put a larger one in there eventually and I have adjusted the height for the lift accordingly to fit a 55″ SUHD from Samsung. It will not be heavier than the […]