Camper Van Conversion

Tested all the mains stuff, it all worked.  I also added a second layer of foam insulation to the big wall panels, and put in the extra insulation using the under floor type insulation.  I then fitted the plywood back in place.  So the walls now look more or less like they did when a first started.  There is also now muich more space in the garage, which should make do the remaining bit much easier. 

Fitted the water heater into the van today, there is still the pipe work todo, However we did cut the hole in the side of the van for the flu and get it all water tight.  We also started work on the water tank however the freezing fog set in so we abandoned that one.  I fitted the under cupboard lights, and built and installed the mains circuit, which will need testing tomorrow. We also finished running the the exhaust and intake pipes for the air heater, which keeps the van warm while parked.  As all the gas appliances are now fitted I will have to try to find a gas fitter to run all the pipes and pressure tests.  

Ran all the cabling for the split charge relay, and got it all working.  So the camper batteries can now be charged from the vans alternator while the engine is running.  Also started to clad the cupboard, also did a lot of varnishing.  I also went shopping and I am now the owner of a 750 watt generator, I figured it will charge the batteries if I am parked up in one place for a while.

Started working on the van once again, did some more on the electrics, added a fuse box and bus bars to run the sockets.  The electrics are now setup so all the vans built in kit (lights, fridge, etc) are run though the zig unit (as each supply is only 10 amps), and the sockets run off their own supply so as to allow higher currents.  We also built the frame work for the kitchen locker cupboard and fitted it.  Some more work was also done on the kitchen unit.

Lots of stuff got done today, dad was at work this morning so I built all the electrics.  The first part was the heavy duty cables that join the batteries together, I over engineered it some what using 170amp cable so if one battery is much flatter than the other the current flow as they equalize would not cause a problem.  I then wired in the zig controller, and then into that the lights and fridge.  It all worked first time which was good, the lights made working later in the the evening a lot easier.  Once dad got back from work we cut the hole in the worktop for the cooker/sink and fitted it.  Finally the van is starting to look like a camper van.  I also decided to add some extra insulation, the insulation I've already added does not cover the structural elements, so I decided to use the insulation foam that is used under laminate floor.  I did a test using the rear door, and re-attached the ply board.  It worked rather well, so I will be using it on the rest on the van.

It was a short day today as I had to be in Sheffield for 5pm.  So not as much work as normal got done.  Basically we did more work on the kitchen unit, finishing off all the struts and cutting the wood for the side panels, and the counter top.

The seat rails are done at last, the seat rails have taken forever to complete, but at long last they are finally done.  They did seam at one point to be taking over the whole job, we even had to remove the fuel tank at one point to fit them.  The tank is now back on so we can now drive the van again.  Work also continues on the main kitchen unit, there is still quite a bit todo on that however.

Finished routing the floor and have started bolting the seating in place.  There are still 20 bolts to go however, and each bolt is taking quite a while as we have to keep checking under the van to see if we are going to drill though any thing important.

Things went a little smoother today, we managed to cut the hole in the roof for the sky lite, as well as fitting a sealing the sky lite. Work continued on the seating rails, with us cutting the floor out where one of the rails goes and measuring and marking the rest.  Hopefully the seating rails will be finished tomorrow.

Things went a little slower today, I managed to get most the insulation finished.  Then started to fit the seat rails with my dad.  This started to take much longer than I had expected and we ended the day with the job still unfinished.  What is really complicating things is having to remove the diesel tank because it's where we need to drill holes for the bolts for the seat rails.  So now having done the tank we can get to drilling tomorrow.

The day did not get off to a good start as the Van's battery had gone flat.  Luckily the RAC would come out even though I have a car policy.  After the RAC came out and got it started things went a little smother.  I managed to get to my parents and get every thing unloaded.  Once I started work I got a few things done.  I managed to get all the old ply lining out, and started work on the insulation.  There is still a lot of work to get done, but it's only day 1.

Off to Cambridge today to pick up most the bits I need form Rainbow conversions.  Rainbow are a company that convert vans them selves but they also sell all the parts them selves.

I've been on e-bay again looking for more bits for the van, and I managed to get a few bits mostly a fridge and a gas bottle. I suspect I may be running out of bits I can buy on E-Bay.

My parents seem to have been busy lately finding things for the van. My Dad managed to find me some commercial grade hard waring carpet, he got hold of the end of a role (twice a much as we need) for £15. Its even water proof, it's ideally suited for what we want. My Mun has also been busy and found all the blackout material we need, for £20. So far most things have cost less than I had planned, I will be amazed if this remains the case all the way though the project.