Vivaro camper Van conversion

[Magenta Sunset]

clever!

[cully]

[cully]

top ply cut at B&Q to the correct size this time



trimming up the boards with the vans own internal 240V supply



maybe now you can see how its going to go together

[Magenta Sunset]

what's the blue socket for?

[cully]

what's the blue socket for?

16amp outlet for looping on or powertools

[cully]

Im happy with the bed everything fits, the ply may need trimming before i cover it but thats not a big issue,
the bed is bolted back to the walls of the Van, and also its been tested with a couple of hippo's







just been thinking about the dvla requirement list
Ive ticked off all but number 4 the table dinning area to which i have a cunning plan!


1 a door that provides access to the living accommodation
2 a bed, which has a minimum length of 1800mm or 6 feet. This can be converted from seats used
for other purposes during the day but must be permanently fixed within the body of the vehicle
3 a water storage tank or container on, or in, the vehicle
4 a seating and dining area, permanently attached to the vehicle. The table may be detachable but
must have some permanent means of attachment to the vehicle. It is not good enough to have a
loose table
5 a permanently fixed means of storage, a cupboard, locker or wardrobe
6 a permanently fixed cooking facility within the vehicle, powered by gas or electricity
7 at least one window on the side of the accommodation

[Mighty306]

Must be a relief that you finally cracked the design of the bed - a nice neat solution in the end.  The fixed table will be a doddle after that!

[Magenta Sunset]

something flip-up/drop-downable?

[cully]

Had the foam cut for the matress today
3" matress grade foam

[cully]

heads up guys!
thought id check the spare wheel on the van, only to find 1 securing bolt siezed solid and the other bolt being a locking bolt with no locking bolt supplied with the van!

I have just spent 3hours cutting off bolts,freeing up bolts and freeing the handbrake levers on the calipers

so be warned before you set off on your jolleys check the things you may rely on in an emergency

[Seb_Ryan]

Cables always seize on these.. And the lockers are a pain in the arse! Checked by jack etc?

Sent from my LG-H850 using Tapatalk

[Eeyore]

the matress foam man looks happy D:

[cully]

first night away with the new bed and so much better than the airbed,
the wife said she wanted hairdryer and straighteners so it was a good excuse to book a site with EHU and try all the electrics in the field so to speak.
also took the opportunity to buy and fit a small cheap microwave into the van

so a trip down to Cornwall on Saturday to visit the Eden Project camp up then Lost gardens of Heligan on the Sunday
had a good weekend away

[cully]

getting ready for monday

[Dum-Dum]

Why have you got the front towing eye screwed in, was there a calamity?
Also you've not shown us what you did for a dining area yet.

[cully]

Why have you got the front towing eye screwed in, was there a calamity?
Also you've not shown us what you did for a dining area yet.

towing eye..... somewhere to tie the tarp too
dinning  area not done yet

Need to get ready for track day

[cully]

all old photos here
http://smg.photobucket.com/user/cully/li...t=3&page=1

experimenting with flickr.... from now on

[cully]

so been trawling the forums of late and have found a little, hidden filter in the fuel filter housing that a lot of people don't seem to know about so decided to investigate and give it a clean

its hidden in the filter head


under the little round cap in the top



its a solid compressed filter that ive cleaned out with brake cleaner



it has made a little difference on the pick up on the van




changed my top mount suspension bearings and rubbers last night
the trip to work today was a little strange without the van wandering the road

[cully]

went out to prove a point today
the question was will my van battery charge when I'm on EHU

so going back to my wiring, i had wired a battery charger conditioner into the leisure battery side of the VSR



i wanted to prove that the charging voltage while on EHU switched in the VSR to the van battery
so out came the multimeter and the EHU lead

i measured the van voltage with nothing connected
12.4v



i then connected the EHU lead and switched on the charger
this brought on the fridge VSR
and it also brought on the Van VSR giving me 14.1v at the van battery




so yes to the original question my van battery does charge when on EHU if the charger is on

[cully]

making a start on insulating and lining the rear doors
not sure how im gona do it yet so im winging it

start off by covering the panels the easy bit



clean them off with brake cleaner and remove any scratch damage that may show through the carpet

offer up and cut carpet slightly oversize



spray glue half the panel not forgeting the edges

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spray coat all of the underside of the carpet

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lay carpet over top half working out the creases, glue second half the panel then work the carpet into all the folds not leaving any creases by streaching the carpet to the shape


turn over board and pull carpet over the edges and trim



X2..... stand back and adire your handy work or cuss and swear at the shit job

brake cleaner on a rag will remove any oversprayed glue

[hotrodjacko]

Nice work Cully, keep it up! Been following this a bit as I'm tempted to do something similar (more a day van style for taking the mountain bikes in).

[cully]

thought id add a tracker to the van
so ive bought a cheap 2 wire unit from ebay for £15
http://www.ebay.co.uk/itm/Mini-Real...cl...1822367389

this will need a std size sim card not included
i looked at price options for Pay as you go and contract
but luckily i have an option with my landline supplier that gives me a free sim
which has 250min/500mb/unlimited text
ideal as the unit only sends texts

anyway unit came so went out and fitted it
for obvious reasons im not showing you the location in the van but its just ground and a battery positive



fitted the sim card powered it up and nothing happened!



had to go read the instruction in pigeon chinnes
only to find a small switch on the circuit board that was not mentioned so switched that and all the lights started to flash



now its just a case of working out the instuctions
to be fair it has worked straght out the box
the only thing i have changed are the passwords and the set timezone

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thought today id insulate and carpet the slide door
I stole an idea with the carpet edging upto the seals, it looks smart and finishes the edges,
it also stopping the water wicking in past the seals if you carpet past the seal itself










finished off the side door with a black grab handle for easy closing from inside,
some nice black bolts to fix it and some black pan heads to loose in the carpet.
these fix the top of the slide door panel as the pop on rivets weren't man enough to hold back the carpets

[Magenta Sunset]

widget very similar to this;
https://amazingdiscountworld.com/product...etrackerv1

[cully]

carpeting the rear doors.....
added Rivnuts to the lower section as to be able to secure the lower panel



sharpi mark around the seal with the door closed this will give you an edge to stick the rubber finising trim



rubber trim profile



trim profile stuck to the sharpi line with super glue



a little more foil insulation for the top section of the door





foil edges taped with foil tape as to not leave hard edges in the carpet layer



time to streach some carpet

[cully]

trim and tuck the carpet inside the profile



lift brackets to fit carpet behind for a neater job

[cully]

its true what they say about the intricate things taking the time!
but time is what you need to spend on it if you want it looking neat!

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august we had 3 cracking nights away in Cornwall, back before the madding traffic of the bank holiday weekend







everything worked as it should..........
except for some bum ijit drilled the central locking motor on the rear door when fitting the bloomin internal handle
and its anoying that you cant access the cupboards under the hob when the beds made

other than that the van worked a treat and we also have a microwave now

[partybish]

Love this project, so impressive. Where did you get the carpet from and how easy/flexible was it to fit around the curves and dips in the panels - how did you get away with no creases?

[cully]

the carpet is a 4 way stretch materiel that stretches into and around corners the secret of no creases is to stretch them out in all directions

list of items and where bought

link for the rubber c edging
http://www.ebay.co.uk/itm/UNIVERSAL-BLAC...2775548437

side windows Kit
https://www.vanpimps.co.uk/product-categ...o-windows/

carpet my SWB has used 10mtr x 2mtr length
http://www.ebay.co.uk/itm/5M-X-2M-MEGA-4...2165518446
or if you belong to the facebook groups look for the name "Roman Cain Cooper" he sells the same carpet from the same place but cheaper

Foil insulation
http://www.ebay.co.uk/itm/Solar-Bay-Gold...2030539536
I have nearly used all of what i ordered 1.2mtr x 25mtr

High temp glue
http://www.ebay.co.uk/itm/10-cans-Trimfi...0402791437
ive used an extra 10 tins as i have stuck everything with it including the Foil insulation/plastic fibre insulation/carpet/roof fabric

Diall Loft insultation (plastic bottle stuff)
http://www.diy.com/departments/diall-lof...658_BQ.prd
from B&Q ive used 4 rolls at the moment

240v>12v leisure battery charger conditioner
https://www.amazon.co.uk/gp/product/B00L7XVQ0W
fit and forget battery charger

2.5mm 25mtr EHU cable
https://www.amazon.co.uk/gp/product/B00C1G8EOK
i have bought 2 of these now one i cut up to wire the van, and one i use for the van
it was cheaper to buy a lead at the time than to buy a cut length of 2.5mm flex for wiring

Smev Dometic 9222 sink cooker kit
http://www.ebay.co.uk/itm/Smev-Dometic-9...3109895016
Local cash sale

battery isolator switch = Ebay
12V/24V 10 Way Blade Fuse Box Holder = Ebay
12V Car LED Panel Digital Voltage Meter = Ebay
12V Dual USB Charger =Ebay
12V Car Cigarette Lighter Socket Power Plug Outlet = Ebay
12v 5M 3528 SMD RGB 300 LEDs = Ebay
Wago Lever Connectors = Ebay
25 Amp 2 Pole Rotary Change Over Switch = Ebay
60Amp Midi Car In Line Fuse Holders = Ebay
BATTERY TERMINAL STUD COVERS = Ebay
Flush EHU inlet = Ebay
Leisure Battery 115Ah = Halfords
LED roof lights = Maplins
12v switch control panel = http://www.switchpanel.co.uk
light switch's = Toolstation
socket outlets = Toolstation
16amp outlet = toolstation
window curtain kits = www.Kiravans.co.uk
M5 Socket Flange Button Head Screws 30mm - Ebay Item no 291976614810

[Matt-Rallye]

That is such an impressive level of quality you have acheived there paul fair play buddy carpet job looks better than ive seen on alot of factory stuff!

[cully]

recently bought the plastic step for a minibus to fit to my van, just to finish the floor off around the sliding door

so today i fitted it
needed a bit of trimming to go over the ply floor and the floor covering but its in now

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