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  1. #21
    regcheeseman's Avatar Privileged
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    INTERIOR CONTINUED

    Built this cubby hole


    Fitted the extra battery in


    Not a proper leisure battery but it was the right price i.e. free so it will do for now....

    My lovely wife took the kids to the theatre tonight, so I could do some more woodwork, more of the framework first, the cross braces for shelves and starting to work on the framework for the storage section behind the drivers seat.
    Then I started to cut some ply to make the shelves


    More ply shelves cut and started to line the base of the cupboards with some black vinyl flooring left over from my delica build, then I ran out of glue, marked up some more ply but it was gone 10 and too late for the circular saw so I gave up - this is how it stands at the end of play




    More panel work cut out, my first go at kerfing - cutting slits almost through the wood to form a curve


    Pouring on boiling water is supposed to help...


    And fixed in place



    Tonight I've been making up some curtains, I knew what material I wanted weeks ago and found a duvet set that could be cut up to provide the material and bought a couple of sets.

    So far I've made the curtains for the front screen and the front doors.


    the cooker shelf fits in fine, ran out of time to tig it up so it'll have to wait until after the family holiday.

    We made it all the way to Land's end, here's the proof - well nearly land's end, Sennen Cove.


    Had the minions onboard


    Back home again, and the snag list is a mile long, let the next round of mods commence...


    I was sent a link to an ad on ebay an ad on ebay
    Using this picture

    I've messaged the seller to advise them that they are using my van image and funnily enough the stripes on it are paint and not the vinyl they are trying to flog!
    Strangely enough, this is not the first time... a german seller used a picture of my caddy to advertise the swage line strips he was selling, but my caddy had vinyl stripes not proper trim!

    Having ground my way all the way out of Lamorna cove I decided to lose a bit off my exhaust turn down


    I've given up on trying to find a pair of polystyrene bumper inserts, so reverted back to plan b and expanding foam, first up I wrap the bumper irons with pallet wrap so the foam doesn't stick to the metalwork,

    only to discover the plastic bumper outer wont fit onto the metalwork whilst it's still attached to the van, thus begins an epic 30 minute battle with the 4 bumper iron bolts that initially moved easy but refused to wind out because of the rust on the threads.
    I pushed the bumper into place last night and prayed that the expanding foam would stop expanding some time soon, thankfully it did, and this morning there were a couple of small growths on the underside of the bumper, they can be trimmed off and tidied up fairly easily. I'll have to trim of the excess pallet wrap as well.

    I also found out that LRM removes uncured expanding foam from paintwork with no damage to the paintwork at all.

    Quite happy with how my home made foglights turned out

    A bit of plastic cut from a striplight diffuser and dusted lightly with a satin black aerosol

  2. #22
    regcheeseman's Avatar Privileged
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    Nearly up to date now and to celebrate 12 months of ownership my van decided to throw a bit of a wobbly

    what started as a slightly ominous noise rapidly got worse and turned into a fairly serious misfire.

    I decided to take the van off the road, do the belts, re-time the belts and finish a few other jobs - I've had a new plastic radiator surround stashed in the loft for a while, likewise the two bumper support brackets which had been hacked off by Stevie Wonder when he fitted the bodykit.

    Another job required was to fit the pipes to connect the under bumper front mount intercooler to the rest of the engine, I had some silicone bends and some ally pipework stashed in preparation.

    The biggest problem and the reason I'd probably avoided this job so far was the lack of access and the tight route for the pipe between alternator and the front panel.

    Not an ideal solution but I decided to flatten the pipe a bit to gain the necessary clearance



    Anyone aware of something on another vehicle that might solve the problem of running boost pipe through a narrow gap without compromising the flow too much? Failing that, I need to try and fabricate a part to suit.

    I've been trying to avoid doing it until it was absolutely necessary, but it was making trying to eye things up near impossible, so with a jubilee clamp fitted as a cutting guide I chopped the original turbo to inlet manifold link pipe in half.



    With the 90 degree silicone fitting fitted to the other end of the intercooler and the link pipe back in the manifold upside down (thus keeping the temp sensor) I could cut the pipework to join the two


    And test fitted in place


    I don't do shiny, those aluminium pipes were too much and I found some old scraps of real genuine carbon look bullshizzle

    Got the pipework fitted last night and spent this evening routing the coolant hoses away from the intercooler, moving the loom around to reach the relocated air temp sensor and replaced all the vac/boost lines.

    Refilled the coolant and fired up the van.

    Took a while to start, I've not cured that issue which may be down to the notoriously poor standyne injectors.

    Settled down to a clean quieter idle.

    Let some heat get in and blipped the throttle - it would seem that Rolf Harris and his didgeridoo have been exorcised - by the simple action of timing the pump up somewhere closer to correct.

    Bit more heat in the engine and blip it some more, waa hey! It's revving much quicker and harder than it ever did before; time for a test spin.

    It wasn't bad before, having a noticeable step in the power round about 2500 when it would take off nicely - in fact it was so good I suspected that it had been remapped in the past.

    However, it's all changed now, the step in the power is gone, it's there literally right off idle instead and the power is up right through the rev range. The combined effects of fitting the intercooler and timing the pump up has made a massive difference.

    Well happy.


    Intercooler all plumbed up, bi of a kawasaki fan so had to do the green pipework, just couldn't bring myself to do it for the intercooler silicone pipe as well


    The drop down between alt and front cross member


    And on the other side a much easier route


    The actual intercooler is hung from brackets on the cross member, and the under tray modified to allow airflow through the cooler




    From the front, the caddy van grille keeps it all factory looking



    With the engine warmed up I plugged in vagcom and measured the timing, could see an option for the AJT so stuck with the default 1Z graph which put the midpoint at 60 when I believe it should be 55 for my van. At idle the timing was jumping around, not sure if that is normal but at least it was jumping around the 55 mark, it seems to be running very well so I'll leave it at that.

    Family crimbo shopping weekend, up to Bristol and Bath.

    Decided to take the van, was a little apprehensive as I've not done many miles since fitting the belts and they have all been sedate around town driving.

    I was quite amazed to find the added stomp at motorway speeds and well beyond Obviously the extra airflow across the cooler helped a lot. Not much came past me on the motorway

    An added bonus was that with the new wheels fitted the speedo now reads spot on at sat nav verified 70, when it used to say 79 at 70.




    NERDY GEEKY STUFF - GHETTO HOOK-UP/BATTERY CHARGER/INVERTER


    Been a while waiting for one to turn up, but finally got hold of a broken UPS at work, took a while to get a 12v one rather than the more common 24v ones.

    So what do I need an old UPS for?

    An UPS uses a battery supply to deliver a 240v supply - an inverter.
    An UPS also charges a battery when there is a 240v supply present - a leisure battery charger on hook-up.

    With a bit of modification, I'll have 240v from the leisure battery and a hook up in the van that will recharge the battery - probably never use it but nice to have all the same

    Once it had been scrapped by so called technicians I commandeered it and made it work again.

    Once it had been fixed and deemed suitable for my needs I broke it again




    Chopped down the original front panel



    just so I could extract the original switches and led status indicator panel with alarm.

    Then cut a few holes out with a dremel to allow me to fit a few new pieces


    Most of the re-wiring done, a new switch and voltage meter fitted to isolate the leisure battery and monitor its condition.

    Time to test it



    Seems to work, I hadn't t reckoned on the alarm sounding every ten seconds or so when no mains is present so I quickly de-soldered the alarm sounder.

    See that section I cut out of the UPS case? It was where the original battery was housed. I had no reason for cutting it out apart from the fact it was wasted space and space is a premium in a camper van.

    However it transpired that having that strange cut out was actually a fantastic idea, I could pretend I actually planned and designed this but I'll be honest, it was a complete fluke.

    I originally was going to mount the unit against the side of the cupboards, but when I come to eye the job up I found a much better alternative.

    It needs to go somewhere in the back of the van ideally


    So I removed that shelf and was amazed that the unit would fit in under the shelf and behind the amps in previously unused and wasted space, just need to chop it about a bit.


    a quick test fit, some M5 rivnuts fitted to the UPS case to allow the unit to bolt up to the underside of the shelf


    And working


    Now to refit the leisure battery and carry on with the rest of the interior...
    Last edited by regcheeseman; 29th February 2016 at 01:22 AM.

  3. #23
    regcheeseman's Avatar Privileged
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    And so to bring you (nearly) up to date, some woodwork...

    I was never happy with the fridge cupboard, the runners were too cheap and the construction was quick and shoddy, knocked together to have something usable for summer camping trips I now need to try make something a bit better hopefully.

    The rest of the installed furniture needs finishing as well, there's no work surfaces.

    So starting on the cupboard, I bought some decent quality push to release undermounting ball bearing sliders from Solmer actually I bought two sets, dunno what happened with the set I bought, I needed some that were nearest to 390mm max and for some reason bought some that were 250mm long??? I've bought another set at 350mm.

    Started work on the shelf, the old design was a bit wobbly because there were no sides, it needed some triangulation to make it more rigid.


    Screwed and glued the sides on and mounted the sliders.




    I've started to cut out the work surfaces including a couple of stainless cup holder from ebay

  4. #24
    regcheeseman's Avatar Privileged
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    I have wood for you.

    With the work surfaces cut out, a special friend set to with his router, rounded the edges and cut a rebate in the large hole



    I then cut out a ply lid to fit on top, the ply is warpy and horrible so this may change, the plan is to also use this lid as a table, had a similar setup in my old van and it worked well.

    Test fitting the work surface, turned out a touch too long and too wide so was shaved down.


    The bit at the front of the stainless 'work area' with the manky bit of black silicone needs some further attention to add in the rolled edge, I have done this, took an ages to get right.

    I know it looks like I've taken the front off the sink but it's the cooker shelf, I'm not having a sink as I cannot be doing all that faff with fresh water tanks, pump and a drain/waste tank - just chuck a washing up bowl in the van if needed and buy a bottle of water from tesco - at least the coffee doesn't have that plasticky water tank taste.
    A decent cooker is important to me, a grill is nice idea but they can be slow, besides I didn't find a nice looking grill/hob combo - so the three-burner setup will go back in here. I welded up and re-dressed the original edges where the box was folded up






    I've been having a problem with wind.





    Wind noise, like a window is partly open, I had put it down to either the roofrack or a small section of missing door seal, where the seal is too short.

    However whilst working on the interior I noticed daylight coming in the window - between the frame and the aperture. I taped it up and drove about for a couple of weeks until we got a half decent day.

    The window came out easy enough


    Revealing a small patch of rust which was dealt with before cleaning up the rest of the aperture and refitting the glass

    I removed the peeling scratched limo black tint and added a 'this way up you fool' arrow I made sure that I didn't make the same mistake as the other side.


    Talking of foolish mistakes... what's that saying?

    Measure twice.....



    Cut Thrice?


    To be fair MK1 (right) was cut fine, but when eyed up to the carcase I realised it would work better with a slightly different design, MK2 (middle, with 3 hinge rebates) was fine but a bit warped and didn't sit well.

    Mk 3 is all good - see those three cut outs? Bit Of Damn Good Engineering right there; the control knobs on the cooker sit a bit proud and the holes locate over them - this has the clever feature that you cannot shut the door and leave a ring on by accident - genius huh!

    Note the new roundy edge bit spliced into the front of the cupboard unit with loads of screws - dont worry, merely work in progress, it'll be fine in the end
    Last edited by regcheeseman; 2nd March 2016 at 02:25 PM.

  5. #25
    regcheeseman's Avatar Privileged
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    After a load of fiddling and trimming and cutting and tweaking and fussing and messing and generally twatting about I've got the drop down flap for the cooker in a position to go for a test fitting; the fridge drawer can be clipped back onto the runners to see how the pair work together.

    The door and drawer fitted and closed up.


    Cooker flap dropped down also gives me a small shelf for working on


    Fridge drawer slides open easy on latching push to open ball bearing slides


    Yes it's rough as badgers, but just you wait.....still needs a bit of trimming to fit properly and then it needs finishing properly.

  6. #26
    Dave T's Avatar Moderator
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    I an sure that if you put as much effort into the finish as you have the rest it will look the business. all the best.

  7. #27
    Dangermouse's Avatar Virgin
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    Awesome thread!

  8. #28
    regcheeseman's Avatar Privileged
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    Quote Originally Posted by Dave T View Post
    I an sure that if you put as much effort into the finish as you have the rest it will look the business. all the best.
    Hope so, I've the skills to put things together at a fairly decent standard of finish, but I do lack some flair on the design side, it'll be 'safe' rather than 'wow', I did consider stickbombing or bright colours but fear it might then end up 'naff'

    Quote Originally Posted by Dangermouse View Post
    Awesome thread!
    Cheers, here's some more....


    Had to pick up a fridge freezer on Sunday which meant the bed had to be lifted out, which now means I have to crack on and get the bits of trimming finished so I can get the rear seat back in again.

    I started on the trimming last night, took over an hour just to do the rear section and it's still not finished



    Yes it does look a bit 'sea of anthracite' at the moment, it's much better in the flesh

    Hopefully the new carpet should turn up today, that's been in my watch list on ebay for at least 12 months, I decided I had to buy it, went onto ebay and chose something different instead.

  9. The Following 2 Users Say Thank You to regcheeseman For This Useful Post:

    Dangermouse (15th March 2016),rjhoy02 (22nd February 2018)

  10. #29
    regcheeseman's Avatar Privileged
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    So, nice tidy trimming all finished - what's next?


    Skip duties.


    A tip run, one broken 'merican fridge/freezer (never buy Samsung fridges) off/mis cuts of ply from the van build and a load of scrap metal



    And on the run back from the tip, why not pick up 600Kg of concrete mix to lay the base for my new kayak store 8D



    I fitted the cupboard drawers back in early as a pre-paint test fit and was absolutely overjoyed, where there was previously a rough edge and what looked like too much panel gap between various components is now a perfect snug fit due to the added trim carpet and it all sits in there fantastic.

    No pictures yet as I want to get some paint on and fit the bits properly

  11. #30
    regcheeseman's Avatar Privileged
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    trimming is lush



    Happy with that, look how tidy the fridge door sits, took another set of slides and a new drawer to get right but it's now faptastic.


    Yeah the cooker covers the black bit I can't be arsed to clean up properly


    Not so happy with the wet patch in the corner of the van



    God knows where this is coming from ???

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