1978 Millard 16ft M54550

[2lateagain]

We purchased a Millard 16 foot caravan in July 2012. It had been sitting behind our bit of land on a block at the rear of us. It was amongst a lot of trees, but looked reasonable outside. We talked to the owner and parted with $300.00 knowing that it was in fairly bad shape inside as it smelt very strongly of mould and a lot of timber rot could be seen. Has chassis No M54550 with gas compliance plate stating that build date was 3/1978.



My wife asked if she could remove some loose tiles on the floor and the following is what I came back to a few hours later.



It was decided to keep going as the ceiling was rotted in numerous places and all the doors had expanded like pine board has a tendency to do when it is moist.




Graham

[2lateagain]

It appeared that the further she went with the clean out the more we found wrong and this is what she had achieved after a couple of days. There were also millions of ants that suddenly became homeless.



We eventually found that there was a hole in the roof about 10mm round at the front that was letting all the water in and that someone had put a total new ceiling under the old and had actually drilled through the 12 volt and 240 volt wires with the screws used to attach the new ceiling. Never tried the wiring as it just looked too bad to take a chance with. The floor was so bad the fridge just pushed out of place taking a bit of floor with it so it was a total rebuild or scrap.





Graham

[2lateagain]

What remained was then moved into the garage after having to remove the hatch and just put rims on to get it low enough to go under the car port. The removal of the outside then started in earnest





The roof was removed using some 6 meter long pine and screwing the roof to those and sliding it out the garage door and then stood up against the garage wall until it will be cleaned, sealed and painted and refitted again.



Graham

[2lateagain]

The timber in the roof was found to be almost non existent in some places, so measurements were taken and away we went.





Eventually ending with this.



Graham

[2lateagain]

Every thing was removed from the chassis and this is how we turned it over to make sure that all was OK.



The Boss showing how easy it was to control.




It would appear that the van originally had been on around Australia trip as the water tank had been replaced in Alice Springs and there was lots of red dust in and around the rear section between the interior ply and the cladding. I found that the axle had a bend upwards in the middle so I would think that it has fallen into a deep rut at some point and bent the axle and torn out the water tank. New electric brakes have been fitted along with new springs and axle and then back into the shed.

Graham

[2lateagain]

Mudguards were then made out of gal sheet and a new floor was fitted.



Two water tanks have been fitted along with an electrically controlled ball valve to stop flow from one tank to the other when travelling.



Slight modification to the wheel arch to make sure that the wheel can be removed without having to jack the axle down.



Graham

[2lateagain]

As the windows were corroded through in some sections it was decided to replace all windows with new windout units, so all the openings were modified to suit the new windows. A bike rack has been constructed on the rear, hopefully not too heavy, but I do want my bikes to be still attached to the rear of the van when I arrive.



One of the new floor and guards.



New aluminum trusses were then constructed out of 25 mm channel and fitted into place, the roof had to be put in place to find the correct place for the hatch.



Graham

[2lateagain]

Once we were happy that all was as straight as possible the walls and ceiling were fitted. The first photo from the front to the back.



and from the back to the front.



A few changes have been made to the way that the ply was attached at the front and rear by adding more channel and separating the ply from the outer aluminum cladding, the 12v wiring has been completed for the stop, tail and flasher lights. Extra lights have been added to the bumper of the bike rack to make sure that no lights are hidden when the bikes are in place. All lights are now LED's.



Graham

[boblor]

Hi Graham
Doing a great job on your van, I can see it will last for many years to come with the effort you are puting into it. You appear to be moving at a good rate for a restoration.
Cheers boblor

[2lateagain]

Thanks boblor, have been working on it now almost full time, being retired it keeps one off the street, have hit the wall a couple of times and needed a break, but it continues on.

Graham

[2lateagain]

Now we have started with the cupboards, have all the frames made and the drawers fitted.



Back of the van with the queen size bed across the van under all the bits



240V & 12V Compressor fridge in place



Graham

[murray]

Graham,
Certainly one of the best rebuilds I have seen.
If you get really bored come down to Hobart and bring your tools
Cheers
Murray

[2lateagain]

Have finally found a place for the Microwave, it is on a slide out shelf in the front cupboard and yes it is across the doorway when in use and I will either have to stay outside or inside until it is put away, the shelf will have a locking barrel bolt fitted to stop it sliding out when travelling.



The timber around the hatch which has been finished in clear with home made mouldings around to finish it off.



Some of the LED's over the counter top cupboards, they are switched in pairs, pair at front, next pair are over the sink area and the pair closest are either side of the gas cook top.



Graham

[2lateagain]

Murray, If I was to come to Tasmania I would need a very big truck to get some of the things I need there, I like a challenge, but this one has been a bit more than was first thought. Thanks for the compliments.

Graham

[Deleted]

Very nice work. Would love more pictures of the cabinets, they look well done

[ForumMod]

What an astonishing job!! The words 'thorough, meticulous, fastidious, etc' come to mind when I look at what you've achieved!


Good on you, and congratulations on turning a sow's ear into a magnificent silk purse.

cheers,
Al.

[2lateagain]

As requested bricktop more of the interior.

Looking from back to front



Through the side rear window



and from the front to the back



Thanks Al, it has even surprised me how it has come out. We wanted to do it in Tassie Oak, but that is no longer available in 3 or 4 mm ply so all we could find was Meranti/Maple and even that was hard enough to get in some reasonable sheets, but it has pleased the Boss to no end. Found with the clear finish we used it just gave a nice surface without making the colour of the timber a lot darker.

Graham

[2lateagain]

A bit closer photo of some of the nice wood grain that has shown up after painting.



The cupboard over the seat area, which will be for my electrical bits, computers etc.



All the top cupboard doors have stays on them to allow easy access.



Graham

[2lateagain]

Photo of the battery box under the seat, it will eventually be sealed with rubber around the top and be vented to the outside.



The instrument panel. Small switch on right controls the valve on the second water tank. All 12v circuits are fused and the relays operate the stop/tail and flashers. I felt that the wiring on most modern cars is sufficient to operate the car, but adding a few extra meters on the back is not going to give a great light at the back of the caravan, so all operate off the battery in the van which is charged from the car when travelling and has its own battery charger when on 240v. All lighting is LED, only 250 v is power points.



When I went looking for cupboard knobs, I was unable to find anything that appealed, they were either chrome, plastic or just did not appeal. Some looked good from China, but experience has taught me that when buying a few from China you sometimes get a few of the type you want and the remainder do not match and it costs too much to send back, so I ended up making my own out of scrap, only had to make 46 to have a couple of spares. All turned up on a wood lathe.





Graham

[2lateagain]

Was a bit annoyed that the fridge came without a finishing surround, one available at extra cost, so I made my own.



Another couple of the grain in the doors.



The seat, table will be in front and we get in from either end, Like the idea as I can roll from the seat into bed



Graham

[Deleted]

Cheers. Me loves cabinetry porn

[murray]

Graham,
Can you bring your lathe down to Tassie too ?
Cheers
Murray

[2lateagain]

Murray, That means an even bigger truck, soon be up to a small semi and I no longer hold a licence for one of those, sorry about that.

Graham

[Deleted]

These caravan accidental renovations are so inspiring. I'm also in Tassie and accidentally started renovating my old van too. I have a long way to go, but lots of idea to help me complete the job thanks to other who have gone down the same path.

[2lateagain]

Just thought I would add a photo of a vent I made, was supposed to go at the top the fridge, but it was too big for the space so I have added it to the end of the cupboards, it will still do its job there.



We have also added the drop down legs, they should be short enough to be used in a vertical position when the tyres are fitted. Finger crossed



Graham