VF Caravans, Majestic Leisuretime D294

[Zippo]

Here's a trap for young players. The nicely made switch panel has switches, fuses and lights to let you know what's on or off. $20 Saturday morning BCF special that looked way too good to pass up. The trap - when all switches are on, no load connected, lights blazing away to show the switches work - the thing draws 3 watts. Decided to remove it and go with a blade fuse panel instead. Fuses and circuit breaker will protect everything but I won't have the luxury of switches. I'm now at version 3 - a longer fuse block to add fuses for the12V fridge, water pump and Range Hood. Has a couple of spare fuses now so won't need to change this bit again.

Version 1 Power Panel - switches, fuses and indicator lights:

[Deleted]

Maybe it is me but 3w is SFA in the over all scheme of things unless you have very marginal power storage   a small led TV will draw more on standby and through the day when there is solar or charge from the tow vehicle or when hooked to 240 shore power that 3w will disappear if it is a problem switch stuff not used off when going to bed  , we make a point of not leaving the water pump or aux outlets on at night just in case   our power board in the Sunliner motorhome draws .1 Amp when everything is off 

[Zippo]

Been a bit hot for the last couple of months so not much progress.

Rewired the switch panel to stop the red lights but still using the external blade fuse holder. Can't get 2AG fuses locally but can get the blade fuses anywhere so I'll just stick with the blades. Also good not having the bright red glow at night when all the power is on. At night, lights out is now lights out - and a lot less bugs They seem to like the light. 

Have done a bit more in the ensuite. Fitted a 350mm hatch with a 12 volt fan to vent the shower and toilet. Should also be able to use the builtin fan to help purge the hot air if the van has been locked up on a hot day. Van is under a shade sail cover so can't tell yet if the fan is going to be useful in promoting some extra air flow. I'll add a photo of the hatch later after I tidy up the wiring. Next on the list is the water to the shower and toilet, fixing and sealing the shower tray, followed by fixing the toilet and cutting the hole in the side for the access door.

Made all the framework to install the second bed, and then pulled it all out again to make room to lay the floor covering. I picked a covering that doesn't have any lines to give away any of my cabinet work that isn't quite square. No one will see if there is a bit of runout in the framing.  

Slowly making progress. It's not about the destination, it's about the journey.

[Zippo]

May 2017 Update - A lot more pictures here  Up to 120 pictures of the rebuild.

Kitchen slide out wire baskets



New suspension kit - Huntsman 2500KG springs, 60mm round axle and 235x15x10 ply LT wheels.
TBA

12 inch electric brakes
TBA

[Zippo]

After 2 years, we're mobile again. In the picture, I'm part way through washing the outside (in the pouring rain) before heading to the weighbridge for the first weighin. Tare on the docket is 1360Kg's. Axle group is set by the springs at 2500Kg's, (wheels, axle / bearings and brakes / breakaway are 3T rated) ATM will be set at 2200Kg's which is much higher than what I need and lower than the Axle Group rating, but I won't have to worry about how many pairs of jocks I pack. It's unfortunate that suspension kit I used didn't have anything between 1600Kg's and 2000Kg's. I estimated I needed 1750 and could have got there (right on the limit) by using GTM of 1600 and ball weight of 150Kg's for an ATM of 1750 and no margin. 1750 was an estimate based on the remaining fit out plus the usual food and clothes etc. So might have been right, but usually something is forgotten and over the limit we go. The price of the 2500 Kg kit was only $50 more than the 2000Kg kit and the 2500 kit has 3T axle and bearings, BUT needed more expensive 15 inch wheels and tyres. So 2500 kit it was and plenty of margin on all the ratings so that's what went under it.

To put it in perspective, the gutted shell weighed in at 950Kg's - could never figure out where all that weight was. So I've added 800 odd Kg's to the empty shell including new and heavier drawbar, 2 solar panels, AGM battery, Inverter,  2 king single beds with memory foam mattress, 168L fridge / freezer, BBQ, 95L water tank and a grey water tank, shower and toilet / ensuite , gas cook top, gas hot water, 2 9KG gas bottles, microwave, Awning plus shade cover and poles, new HD suspension, 3 higher rated wheels, and lots of storage. All adds up. Outside looks original but inside is comfortable.  

Still a lot more inside to finish but the end is in sight.  And ......... The Wolseley 6/99 is off the list of tow vehicles. Would be a big ask to drag 1800K'g behind it. The high finished weight came about via project scope creep - things not in the original plan kept getting added. Anyone  doing a reno knows that you need to keep the Ministry of Finance happy. We plan on doing some longer trips and sneaking up on retirement so we'll enjoy the extra comforts I've built in.


Rebuild pictures

Off to the weighbridge for the first weighin:

[Mustang]

WoW what an effort, you now know every corner of your van, wonderful skill.

Like you I'm surprised at the empty weight??? but your ATM is well in check, keep us posted. Noticed your Treg hitch, but no handbrake?

Cheers
Brent

[Zippo]

Hi Mustang.
No hand brake yet, just mobile enough to get to the weight bridge and back (just down the street and back). Hand brake bracket and something to mount the spare wheel have to be welded on yet. Other than those 2 problems, the welding is finished. Some small utes have a winch system to load and unload the spare from underneath. Trying to find one to have a look and maybe rip off the idea. Have 125Kg's ball weight right now so room to move there for an under the drawbar spare. Front to back balance is pretty good but drivers side weight is higher than left side -  extra battery will fix that.  None of the gas is fitted yet. Most likely have that done after rego and just update the records later. Will only need a hard line for the cooktop and an outside bayonet for the BBQ and hot water system to share.  

Still lots of jobs to do before the first trip out - first weekend in August Need to focus a bit more. 

[Zippo]

Passed the RWC with flying colours   We are officially registered and allowed to use the roads. It will still be a while till we are out and about. Still have a lot of fit out work to do inside but I can now move the van to different places as I need specialist work completed - the gas fit out for starters.

[Mustang]

May 14, 2017 10:37:55 GMT 10 Zippo said:

Still lots of jobs to do before the first trip out - first weekend in August Need to focus a bit more. 

Have a look at Page 1, then you will see how far you have come!!!!!

[Zippo]

May 31, 2017 18:02:27 GMT 10 Mustang said:

Have a look at Page 1, then you will see how far you have come!!!!!

I know, boy do I know - I look through the photobucket album regularly just to remind me how far I've come. Like all these large scale restoration / renovations, its been a journey and a bit of a rollercoaster at times. I've tackled jobs I never even dreamed I would be trying, let alone coming up with some pretty good result. With these jobs, I know and see every little imperfection and every thing not quite up to my self imposed standards. Either people having a look at the van don't see any flaws, or they are far too polite to say anything. Although it is still a way off finished, people are surprised at the layout and just what I've managed to fit in to such a modest van. All things considered, feeling pretty good about my work and looking forward to some weekend R&R in the not too distant future.

Can only be weekends away for a while as my wife still works fulltime (I retired early ) and she doesn't want to retire till end of 2020 when the last child we care for finishes school and goes out in to the world. So, I've got 3 years to learn the caravan craft and fine tune the van before we do some longer trips and maybe get lost and not find our way back for 'quite a while'.  Also, working on the van has been good therapy for me in the first couple of years after I retired. Busy every day, you get to see the results and the satisfaction of doing this work is enormous.

I'll post some more pictures as we move along - it's all coming together now.

Oh - Just been informed the August trip is to Elliot Heads 11th, 12th, 13th and back home 14th - 4 day weekend based on regional public holiday for the Brisbane RNA Show. Nothing like a deadline to sharpen the focus - and caravaning friends from work are coming too - the Majestic Golden Oldie and the brand new Goldstar on tour. No pressure

[78466noM]

looks good and is a credit to you.

[Zippo]

Getting down to the pointy end now - first away is this weekend overnight 8th July. Been busy last couple of weeks building and painting cupboard doors, installed the vanity, started on the water works for the shower, sink and vanity, finished the toilet installation (not tested yet), installed a second battery, changed some of the wiring round the batteries, set up the 32 inch TV on the wall mount and made the antenna mast. 240 Volt power points and RCD installed and tested. Also installed the electric brake controller and ran the wiring for the Anderson plug in the Mitsubishi. Nothing like a deadline to keep you on task.

Hard bits for this week - fresh water tank, grey water tank and grey water plumbing -- then pack and go

Pictures - well until I know where to  after Photobucket, I'll just keep them here. Going to try and save my current pages and photos so I can put the thread back together later when a new photo sharing home is found. Posts without pictures are pretty boring.


Not finished but we're off for the first trip away:

[Zippo]

Photobucket has now killed off my photo links.

Anyway - Saturday was the first trip away. Van isn't completely finished - but good enough for the overnight trip. 2 and a half hours each way so not a round the corner test. Tows nicely, sits close to level without a WDH, but, bit hard to see small cars sitting in close to the back (mirrors can't see round the back of the van for some strange reason) so next job is to put a camera back there to see what's hiding in close behind me and then back to the list of jobs to finish off.

Next trip is exactly 4 weeks away (long weekend this time, 11, 12, 13 and back on the 14th August.) All the important stuff will be finished for the next trip and then after that, all the tidy up small jobs to hopefully get to a conclusion for the renovation. Test run was a success - Ministry of Finance is happy with the result of all the work. Also got good feedback form fellow campers where we camped - they all loved the van especially when the overnight temp dropped to below 5 degrees overnight and we got up early and did pancakes for breakfast for them round the open fire  

[Zippo]

It's a week to go till the next outing Still finishing things off.

Milestones:

• Finally got water and power to the toilet, water to the sink, hand basin and shower.
  
  • Water to the back of the van for the gas water heater - heater will run off a bottle till the gas lines are installed later
• Waste water plumbing installed and works
• Installed a pressure reducer on the Mains water line
• Built three drawers for the big cupboard
• Set the DC power up so I can only plug either the battery charger or inverter in - but not both. Would be bad to have the battery charger plugged in and charging the battery from same power supplying the inverter that is supplying the battery charger - bad kind of loop.
• Ran the power through the drawbar for the DC-DC charger (from the anderson plug on the towbar) to charge the batteries while on the move.
  
• Fly screens in to the 4 seasons hatch

 
To do this week before I go:

• Install shower screen - not as simple as it sounds. I have to remove the glass from the door frame and replace it with a sheet of the lamipanel I used on the walls - much lighter and won't break.
  
• Run the TV cable from outside to inside (have the special through the wall connectors)
• 2 more powerpoints need to be wired in - for the microwave and kitchen bench (for the jug - coffee)
• Mount the drawbar tool box and gas bottle brackets
• Make and mount the pole carrier on the drawbar

Later:

• Solar panels on the roof
  
• Doors on the big cupboard and hanging rail in the cupboard
  
• Satellite setup (for the Foxtel box)
• Plumb in the water pump for off grid camping (it's there, just not connected yet)
• Install a grey water tank
• Build a rear bar / spare tyre carrier / gas water heater mount
• Install rear view camera
  
• Recheck weights and balance - ATM is, and will remain inside the limits - need to keep track of the ball weight
  
• Do more trips
• Put the photos back in this thread

[atefooterz]

Nothing better than getting those checklists ticked off! (apart from image hosts that stick around without blackmail)

[78466noM]

Those lists look big but the original list would have been massive.
   I was hoping to get a couple of shake down runs like you have done but time won't permit it so all I can do is make sure I have every thing I can think of done and write down what needs to be done when we get back.

[Mustang]

Great work their Zippo, I like your lists, small chunks breed success.
Tip: think about mobile solar panels, there is only a small window of charging through a fixed roof panel, especially in shady areas.

[Zippo]

Aug 7, 2017 8:25:31 GMT 10 Mustang said:

Tip: think about mobile solar panels, there is only a small window of charging through a fixed roof panel, especially in shady areas.

Thanks Mustang, but too late for that one - already have 2 x 200 watt panels. If time to charge is a problem, I'll supplement with a portable panel.

[Zippo]

Aug 5, 2017 7:52:16 GMT 10 Zippo said:

 
To do this week before I go:

• Install shower screen - not as simple as it sounds. I have to remove the glass from the door frame and replace it with a sheet of the lamipanel I used on the walls - much lighter and won't break.
  
• Run the TV cable from outside to inside (have the special through the wall connectors)
• 2 more powerpoints need to be wired in - for the microwave and kitchen bench (for the jug - coffee)
• Mount the drawbar tool box and gas bottle brackets
• Make and mount the pole carrier on the drawbar
  

Welllll....... the time to move out has arrived. Leaving about 8:00. Will have to top the fuel up as I leave town and hit the road.

Got all the tasks listed above completed and added a mount for the TV mast / antenna. Only need the antenna till I get the satellite dish set up - hopefully before the next little outing the Harvey Bay in 2 weeks.

Measured the ball weight at just over 180KG's so still on track with the weights (that's a relief). 

Elliot Heads just South of Bundaberg is the destination - about 3 hours normal travel so by the time I stop for lunch and have a look a some of the sights on the way, maybe 5 hours plus. That will test things out, especially the Challenger and the packing  

[Zippo]

Arrived safely without any real dramas. Lucky I stopped about 10 minutes after I refueled, to move an annoying rattle from some of the 'must take' bits in the back. Did a quick check inside the van at the same time - forgot to lock the fridge and freezer doors didn't I. Everything was on the floor. Minor mishap and easy fixed.

Nice caravan park not far from the water. First time I had to back a van into a confined space. Guy from the park guided me in OK. Power and water are working - no leaks so I'm really impressed and so far the layout is working well. Had a  few people come over for a look. Most wouldn't trade their new van for mine but thinks it's pretty functional. (32 inch TV and the fridge / freezer gets them every time )

[78466noM]

you reminded me of another job I have that is to make a stronger latch for fridge when traveling

[Zippo]

Final target is now 2000 / 200 KG's with 85L of water in the tank, grey water tank fitted, annex stored, food in the cupboard, satellite dish stored somewhere - everything loaded ..... Last weekend we built and fitted the rear bar / spare tyre carrier - 8M length of steel is 34KG's and we used most of that building the bar. All the cupboards inside now have doors, catches, handles and shelves or storage baskets fitted. Inside is pretty much finished (including getting the Foxtel box installed and working). Dropped the van off at the gas fitter yesterday for the gas line to the cooktop and 2 bayonets (hot water heater and Baby Q) to be fitted and certificate issued. 2 weeks before we head off for another weekend away - Chinchilla this time to listen to the community orchestra play and have a look around the area.

I'm still taking photos and will update the thread to fix the busted pictures. Haven't loaded any more to Photobucket but everything is still there and accessible as long as I only point to the collection - not any individual photos.

Photo Collection

[Mustang]

Just had a peak at your photo collection, some serious hours spent there, great job.

[Zippo]

A couple of real plumbing jobs got in the way of finishing my 'small' gas job so van won't be ready till Thursday afternoon.

Finished jobs before heading off on the 6th October for another weekend away -

• Picked up a portable, folding 120 watt solar panel for $120 delivered. It can supplement the 2 x 200 panels if the van is in the shade. Another Anderson plug needed to wire it in.
• Finished all the cupboard doors, shelves, handles and magnetic catches
  
• Satellite / Foxtel setup was easier than I had been lead to believe it would be. Seems I still need the antenna for the Free to Air Channels (old version Foxtel box and so far, no VAST box)
• Rear bar and spare tyre carrier are on. Needs a bracket to hang the portable gas hot water unit from. Hot water is at the back to be closest to the shower and waste the least water getting the hot water running.

To-do list (to be finished for the Christmas outing)

• Annex - Thinking about using a 'freestanding' annex like this. Check the video clip on the bottom of the page to see how it works - Freestanding Annex
• Finish freshwater tank / greywater tank
• Put one way valve between pump and mains pressure water line
  
• Reweigh the van fully loaded

[78466noM]

I looked at something like the annex you are looking at but I have never had any luck with polyester tents they are light but more care is needed to stop holes now canvas is much hardier but if no kids there shouldn't be a problem .Your van looks very nice and tidy have to keep your photo's away from the wife it will give her more ideas for me to do to ours have a good time away.