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  1. #1
    chally69's Avatar Privileged
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    Custard cream build.

    Hey all thought I would put my build thread up on here for all to see, this started November 15 and will be ongoing "forever" probably. Hope you enjoy.
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    Proud new owner.

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    Van had already had a conversion but the layout didn't work for me, time to change it about. Overwise besides a few small paint issues the van was in real good condition. 105k on the clock I was told on sale no service history but when I was looking through the owners manual a found a service book stamped from new upto 98k. What a bonus, first thing, just to ease my mind timing belts and water pump.


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  2. #2
    chally69's Avatar Privileged
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    On removing the old install I started to discover a few problems. I think the guy who done it cut a few corners. To start with the whole of the inside was lined in one piece, not that this is a fault but it does make it difficult to do any work to the panels. I ended up cutting into it and later I'll cover the panels individually. Now I discovered that the panels were full of fibre glass, on researching insulation I wound out fibre glass absorbs water and will rot the panels from the inside. At this point everything came out and a good clean took place. After a lot of research I chose to use a mixture of sheeps wool and recycled plastic bottles for warmth and sound deadening. All this was then sealed in with silver bubble wrap to act as a vapour barrier.

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  3. #3
    chally69's Avatar Privileged
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    Before sealing it up with the vapour barrier I ran a load of plastic copex in so any future wiring can be fed through these.


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  4. #4
    Dave T's Avatar Moderator
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    The codex is a good idea, so often you plan what you need in the way of wiring, lay them in put the panels back and then realise you have forgotten a wire for a switch or whatever. Keep the pictures coming we are all
    Interested in what you do. Good luck and should you need any advice then don't hesitate to ask.

  5. #5
    Dan's Avatar Administrator
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    Coming along nicely Chally



  6. #6
    chally69's Avatar Privileged
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    Cheers guys the van is a lot further on, I just need the time to input into here.


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  7. #7
    chally69's Avatar Privileged
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    Time to sort the floor out, after removing the old ply floor which had been screwed into the floor pan I discovered a few other bits. The tie down bolts were missing and had let moisture in so a bit off surface rust there and where they had drilled the ply for the table support there also drilled into the floor- muppet.
    So action, grind all holes of any rust, treat with krust rust protector, etch primer, pop rivit small holes with a dab of sealant and then hammerite paint top and bottom. Hopefully this will sort it. Oh yer also replaced the tie down bolts. Click image for larger version. 

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  8. #8
    chally69's Avatar Privileged
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    As I have done with the rest of the van I want the floor to be as insulated as I can without loosing too much height.
    Rather than undoing what I've just done I am sticking 9mm bits of ply to the grooves in the floor with tiger seal. These will then act as a base to screw the floor to. In between these I am using high grade under floor heating underlay. All this is then covered and sealed up with silver bubble insulation.
    I opted on putting a 12mm ply floor on top of this. I got a 10x 5 sheet to minimise on joins.
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  9. #9
    Dave T's Avatar Moderator
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    That looks a first class job, and as they say if a jobs worth doing it's worth doing well. Keep the pictures coming.

  10. #10
    chally69's Avatar Privileged
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    Got the roof plied and carpeted and installed some LED lights. Side panels also carpeted and fixed, I got the Carpet from mega van mats real good stuff and real simple to do. It's starting to take shape now.
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