Still No Insulation

I got in touch with the supplier of the insulation via ebay on Friday, but it was too late for anything to be done.

He contacted me this morning to say that FedEx reported they tried to deliver Thursday and no one at home so they left a card. This is a total lie, I was working on the van in the drive at the front and I can see every vehicle that goes past, let alone stop outside and someone to walk up the path at the side of me. But they will be attempting to deliver again tomorrow (Tuesday).

So not a lot done today, wiring put in for the 2 roof lights, and the 2 lights taken down from inside the caravan.

Started to take out the toilet from the caravan, so that's already to be put in place when the time comes.

Did a lot of measuring to see how things are going to fit, still not sure how everything is going to go, but I have decided to put the toilet at the back on the nearside, with a false wall at the back so that the cassette can be taken out through the back door, as opposed to cutting another hole in the side of the van, I think then the kitchen unit will go from the toilet towards the front and will overlap the sliding door, I will have to put the fridge on the other side of the van in-between the long seat and wardrobe. I am thinking that the cooker takes up a lot of space and is very rarely used, so I may use the space to put the microwave in and an extra cupboard.

Homebase tomorrow (Tuesday is 10% off day for old fogies) for a couple of bits and pieces plus the vinyl tiles for the floor and some PVA adhesive to seal the plywood floor before laying the tiles.

 

 

 

The cables in place for the 2 roof lights, taped to the side of the ceiling strut, I used the cable that had been used for the existing interior lights and stupidly cut the spade connectors off the end; when I took the lights down inside the caravan they too had spade connectors and the cable would have plugged straight in.



Cutting The Floor

Although we live out in the country, we are blessed by having a small trading estate just one mile away, on the trading estate are 2 timber merchants, 1 builders merchants (and one being built) and a Homebase. So a lot of the materials needed for the conversion are just a couple of minutes away.

You would think with the competition that prices would be similar, but after phoning each one for prices of 9mm and 4mm plywood I found a big difference in prices.

I just needed the 9mm for the floor today, but priced the 4mm at the same time, the prices were (Builders Merchants) 9mm £13.68 - 4mm £11.30 (Timber Merchant A) 9mm £15.84 - 4mm £7.68 (Timber Merchant B) 9mm £16.80 - 4mm £9.40.

So the builders merchants got my trade today for 3 sheets of 9mm for the floor, and timber merchant A will get my business for the 4mm for the roof and sides, timber merchant B loses out, but incidentally timber merchant B was the cheapest when I bought some decking last year.

 

 

 

The 3 sheets of plywood swallowed up in the back of the van, it is great to be able to buy this stuff knowing that you have no problem getting it home on a roof rack or similar as in the past.

 

The first board uses a full 8' x 4' sheet with a cut out for the wheel arch, the old piece of flooring was used as a template for the cut out.

 

The first piece in place and the second piece marked out for cutting, again using the old floor as a template for the wheel arch and side door pillar cut outs.

 

The second piece marked out and ready for sawing, the back of the van being used as a saw bench.

Both pieces in place and I am glad to say they fitted perfectly, now just the front piece, just a little too wide to take out of the previous sheet.

The last piece in place, I still used the old floor as a template even though no cut outs were needed as I knew it was a perfect fit.

All done, quite a bit left over, but I am sure it will be put to good use as the conversion proceeds. I just hope my insulation arrives Monday so that I can get the floor insulated and then the plywood screwed down and then a coat of sealer before the vinyl floor goes down.

Preparation Complete

 

The grubby floor after lifting the plywood, it needs to be spotless ready for the insulation and new plywood floor.

 

First job washing the floor with hot soapy water, and drying off with another clean cloth as I moved along, the floor is now dry and ready for the next step.

Some small rust holes where the screws have pulled out when lifting the plywood and a few minor places along the wheel cover joint, a wire brush and some wire wool got rid of the rust.

After the wire brush another clean out so that the areas that need it can get a couple of coats of Hammerite.

The side door sill had taken a bit of a battering but looks like new after de-rusting and painting, all the screw holes along with any bare metal had a couple of coats of paint.

 

The seal from the bottom of the bulkhead had to be scraped off and again a couple of coats of paint.

 

All done and ready for the floor insulation and new plywood floor, the only problem the insulation has not arrived and it is Friday afternoon, so not much chance of it arriving before Monday now.

Out With The Old

Some of the items I ordered from ebay arrived in the post today, cable, battery terminals, crimps and a 240v inlet. Still waiting for a few bits and bobs including the insulation. I have ordered some self drilling screw as used by RickVanMan on Youtube, I hope they work when the time comes to use them.

 

 

So on with the next job, one of those jobs you don't fancy doing but it's got to be done, removing the cargo strapping points and taking up the old plywood floor.

 

An essential tool for removing the strapping points is a set of good quality star bits similar to the ones in the photo, they are for use with a socket set and believe me the long bar was needed on a few of these, I got this set a couple of years ago for some minor job and I am glad I got the full set as a different size bit was needed to take the bulkhead out.

 

7 of the strapping points were removed quite easily but even with the best of tools there is always one stubborn one, It came out part way but even after plenty of WD40 it refused to come out any further and the bit started slipping and rounding so time for the trusty B&D electric saw.

 

Most of the screws holding the floor down came out quite easily but some the screwdriver was slipping on, so it was a matter of tearing up the plywood and pulling it through the remaining screws

 

The offending strapping point with the bolt cut off level with the floor, this is the B&D saw which cuts through anything, with different blades for different material, the shoe and blade also turn 90 degrees so that it can be used as a jigsaw.

 



 

All the plywood out and the screws that were left in have been cut off flush with the floor, one bad thing the wheel arch covers had been screwed through the side of the wheel arch which had got quite rusty but only on the inside.

The floor is all brushed out ready for washing, attacking little bits of rust with a wire brush and then paint with Hammerite

Then it's insulation down and the new plywood floor.

Fitting The Windows

I have decided on none opening bonded windows that keep the lines of the van. I think they look much better than different shaped expensive opening windows. But everyone has their own opinion on which to use.
I had considered fitting them myself but opted out for a fitting service and found a supplier who comes out to you to fit them at a very reasonable price, much better in my situation,

 

Hole drilled and the panel being cut from inside using a jigsaw, the fitter said he has tried the different methods of cutting the panel and finds the jigsaw the best method.

 

The opening cut in the panel

 

The other side cut out

 

The edges filed and anti rust paint applied

 

The special beading in place round the cut edges

 

The panel primed prior to the mastic being applied

 

The first window primed and ready to fit

 

Applying the special mastic

 

After a few minutes the window is bedded into the mastic

 

Tape applied to hold the window in place till the mastic dries.

 

And that's it job finished in less than an hour, in 2 hours time the van will be OK to drive

Stripping Out

The first job is to take out the plywood lining and the bulkhead ready for insulating and putting in the side window.

 

 

The bulkhead has to come out.

A nice flat are to install a roof vent.

 

Baxter & Bailey taking an interest in procedures

Most of the plywood lining removed

 



 

The bulkhead removed

 

Everything stripped out, ready for a wash down

 

I cut quite a bit of the bush down so that the van wood fit straight on the drive.