New van build ( Again )

For those that are about to embark on a van build, all I can really advise is to measure once measure twice measure three times. Test your results physically with what you are fitting, and if your happy with the result cut that panel out with confidence, but always in the back of your thoughts is if I'm wrong how can I make this mistake good. I.e. Never throw out sheets of steel cut out from other sections until you have fitted all external fittings as that piece of steel could be between abject failure and a super bodge that makes the job right. Phil

Still at it slowly, just a couple of photos of the rear side windows with 4mm ply affixed almost ready for stretched carpet covering, spent a couple of hours yesterday separating all the coloured 12v wiring from their corrugated conduit, I believe as I mentioned before that there is more than enough to complete the wiring requirements of the build.
I'd like to take this opportunity to wish everyone one this site a Very Merry Christmas and a productive New Year. Phil.

Very good methodical work.

Just as quickie today, I had fitted a rearview/reverse camera built into the rear high stop light unit and a clipped on monitor to the rear view mirror ( Which I had to purchase separately).
I'd picked up both the monitor and the camera power from a random electrical block hanging around by the o/s rear light unit, it wasn't being used and I have no idea what would have powered had it been plugged in, but I'd tested it out and it only became live with the ignition switched on and or with the engine running. All seemed OK till I took the van out to buy some more ply at which time I noticed that there was significant ghosting happening on the monitor, Hmmmm.
I then unsoldered all my previous connections to this block and powered the camera and monitor strait to the liesure battery, and all was well with the quality of the picture with just the ignition on and with the engine running. I had initially when setting it up connected straight to the o/s rear light and had the same ghosting problem. The supplier of the camera had when I'd phoned him about another problem suggested that there is a problem of interference on the monitor when fitted to Ducatos/Boxers and Relays, so when I'd put it straight to the liesure battery and all was well, I realised that I'd have to use a relay so that ignition live on this block only triggered the liesure battery cct for the camera and monitor which then became a totally independent power supply from the vehicle power system and sorted the ghosting problem. Before I finally tightened everything down I made sure that the relay being triggered from this random ignition live, did not effect the Canbus.
Just fitting this rear view/ Reverse camera has taken a good 4 or 5 hours due to this problem.
I've fitted atleast four of these to Relays boxers and Ducatos and never come upon this difficulty but then this is the first 2017 Sevel van that I've converted all the others were 2016, 2014 and 2005 models so I can only assume that the Cambus electronics are slightly different on later models. So if you get this ghosting problem or bad interference, then you would have to use a relay triggered by ignition live. Phil.

Making slow but steady progress over the last two weeks, I've now as can be seen in the photos now placed the cieling up with all the associated wiring for the lights. The lights apart from the rear heki lights are not in their final place as I've just double taped them up conveniently so I can see after 16:00hrs.
I have also finally fitted the two back windows, as there has been two good days of sunlight which enabled their fitting, I've not given a blow by blow account of how to fit them but if asked I will add that sort of info for those that have not fitted exterior privicy glass before, it can be quite nerve racking for the uninitiated, so if required please ask and I'll give the relevant info on fitting them.
I have also fitted and routed the solar panel cables through their waterproof mounting box ready for fitting a 200watt solar panel when I get another good weather day.
You can also see that the rear side panels have been cut to size and appropriate blocks have been glued to mount the panels before the furniture is fitted and stretch carpet mounted in visible areas.
All electrical cables have been routed throughout the van for lights, radio, toilet, water heater and TV.
It seems to spectators on the side that not a lot has been over the last two weeks but believe me a lot has been done as it all takes time, not only physical work but standing back mentally and deciding what's what and how to proceed to the next step. Phil.

Continuing on, today the Gaslow 6kg bottle and filling kit arrived from Hamiltons in Northern Ireland, they were considerably cheaper than other suppliers and it was only a two day delivery.
This meant that I could now fit the fill valve and the water fitting. The area that was available for both was extremely tight as the only place that they could be fitted was directly behind the n/s B pillar and before the n/s wheel arch.
Measuring and finding the floor height outside and making sure I had missed the B pillar moulded steel was quite frankly intensive, but with care and multiple measurements, I marked the centre of both the gas and the water fittings onto the outside of the van and drilled an 2mm hole through the centre of both, so that I could safely check inside that the larger circular cuts would mis the wheel arch and B piller. I won't show the actual cutting of the holes but the gas apperture I used a 70mm hole saw and for the water aperture I used a compass to mark out an 80mm dia circle, after which the usual drill holes the size of my jig saw blade and proceeded to cut out the circle.
I think I have mentioned it in the past, the best way to cut out in tight areas is to remove the jig saw foot and use the guide roller as a very short foot. By the way it may be my personal choice but my preferred method of cutting appertures in the van sides is with a jig saw, I really can not understand why people insist on using a disc cutter as sparks fly everywhere it's noisy and difficult to keep on a line.
I've put up some pictures to explain the situation. Phil

Hamiltons i think are in Bangor 3/4 hr drive trafic from Glengormley.

Yes indeed Trev, initially I thought they were in Wales Bangor until I heard his accent and he told me they were in Bangor Northern Ireland. Have to say they gave me exceptionally good service. Phil

Cieling and floor now in place, all lights now working and in their correct location, tomorrow I'll start on the furniture. Phil

Progress

Squiffy said:

Continuing on, today the Gaslow 6kg bottle

Click to expand...

Absolutely no criticism, simply an observational question for you Phil.

As gas filling points are getting fewer and fewer in the UK, wouldn't it have been better to have fitted a considerably larger cylinder?

Keep up the brilliant work, I only wish it was me doing it!

Phil