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This time, we are detailing the little bit of ICE work in the rear.
Including a 22" drop down TV and a set of 6.5" Rainbow components in some custom roof mounted speaker pods.
TV
We were lucky enough to pick up this Pyle 22" (PLVWR2200) drop down for £170!
For some reason after we bought it, they shot up in price and are still around £300 now. Very lucky I think.
So, to Fit the TV, making sure it would be solid, we went with wooden batons, attached to the roof ribs.
First we screwed some wood to the ribs themselves, so it would be easier to link all the extra batons together.
Then, using some drilled metal strips, linked them all together.
We used the batons to lower the level of the base of the TV to be 100% sure it was in the right place to sit flush with the ply roof when we reinstalled it.
Added the metal base that came with the TV to the batons.
Test fit the unit
We chased all the power, sound and vision cables down the drivers B-Pillar.
We also added some struts on the far left and right of the TV, for the speaker pods we were about to build....
Speaker Pods
Time for the Rainbows! Love the sound of these things, nice and warm.
Once more my able assistant stepped up.
Measured out some small basses, using the size of the speakers as a starting point, so the pods would be in proportion.
Made a frame for them using some MDF rings bought on eBay, along with the metal tweeter holder you get in the pack.
Got the angle 'right' by test fitting them in the van to be sure they were pointing at us (On-Axis) when we were sitting on the bench in the rear, for direct sound with as little reflection as possible.
Just took off a little of the MDF ring so the metal ring sat flush. All this will be hidden soon enough.
Bought some stretchy fabric and used a staple gun to secure it all to the base, making a reasonable shape
(N.B. I would spend MUCH more time doing this if I was to do it again, as the thick folds were a REAL pain to sort out with cutting back, filling and sanding)
Looking good!
Get some resin mixed and paint it on, making sure to saturate the fabric.
As I said, it took a LONG time to sort out the back of them, as the folds were a little too thick.
Sanded them down then used body filler to level them all off. Then back to the sanding (Turk would be proud!)
Finally cut out the speaker apertures, only needed a sharp knife for this and came out very clean.
Used some spare Megavanmats stretch carpet that we used for the roof panel to cover them.
Then test fitted the speakers
Pretty happy for my first real attempt at fibre-glassing in this way.
Had to cut a hole in the roof ply (and re-adjust the carpet)
My able assistant wielding the hole saw.
We re-fitted the roof, now with a hole for the TV and some smaller holed for fixing the speaker pods. As well as passing the speaker cables through.
Then, it was just a case of putting the TV up on it's mount again and fitting the speakers.
Still very happy with the setup.
But... If I was to do it again, I'd have the bases of the speaker pods thinner (or maybe even not have bases!)
The fibre glassed structure is so solid, it doesn't need it. Not only making them look better but also slightly less intrusive in the van.
At the beginning of EVERY bloody camping season (and a few times during the season) we will both bang our heads on the one nearest the sliding door!
