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Post by jdmac2312 on Mar 6, 2015 11:50:05 GMT 10
Mmm ,makes me want to look at our roof as well. Mentioned to Kevin about taking the poptop off as it needs a good clean on the underside and will be easier to paint the top when off.
Will consider that in the next few weeks.
Well done so far.
Jacquie and Kevin
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Post by Mustang on Mar 7, 2015 15:37:09 GMT 10
have removed the roof cladding and found some interesting modifications  IMG_20150223_134957.jpg The blue carpet stuff on the ceiling, was hiding the water damage to the ply - I already knew this and had planned on removing or repairing as needed, but I didn't realise that they had used other bits of timber to try and fill the missing section  WTF  ?? |
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Post by Deleted on Mar 8, 2015 7:51:37 GMT 10
Yes people have some strange ways of hiding things don't they
cheers
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Post by Deleted on Mar 11, 2015 16:03:32 GMT 10
Captains log.........entry #
Well I hope to be starting on the inside fit out next week ! The roof is back on but the pop top is still off, I sealed the internal timbers before refitting and sealing the roof, checked all electrical cables and screwed and stapled it back into place. Taking a note of where the new middle awning support is located and widths on the pop top support beams so as to be able to fit the brackets for the new awning. We have decided to get the pop top skirt replaced and will dip into some of our savings to get it done in the next few weeks, also the cladding has had all old sealant removed and I will be re fitting the trim starting this weekend, I have purchased 5 tubes of the flex and seal stuff and will fit 1 of 4 trim and work out how many more tubes I will need to do the other 3 sections - as they are all the same length.
Opened the rear cladding and cleaned away old silicone and ply, removed old staples and fitted some timber onto the ply floor for the new rear wall to attach to, also fitted a couple of alloy "c" sections as well for extra support and to give me something to be able to attach the bed frames to(same as the front) and fitted some pieces of ply behind where the tail light assemblies are going, closed it all back up but used 3/16 cup head bolts on the chassis instead of the pop rivets.
Wired up the fridge to 12v with a new switch and led indicator light( lights up when using 12v) also ran a 15a cable through to the rear and fitted a cigarette socket near the rear 240v power point for any 12v appliance usage.
Hope to paint the "A" frame and finish off fitting the gas and water lines to it and re fit brake cables, also need to fit the water tank and a new inlet pipe.
Lots of just little jobs but will clean them up over the next couple of weeks. Still looking at a mid April or earlier finish date.
Cheers |
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Post by Deleted on Mar 18, 2015 9:37:53 GMT 10
Well another busy week and the job list is growing shorter 
I have fitted and sealed the trim - what a job, that stuff gets everywhere , the "A" frame is all painted along with the hitch, brakes connected, gas bottle and line secured, and the water inlet as well
I have a bit of trim that will go over the join between the checker plate and the original cladding but will fit that once I paint the van.
I also sorted out the last of the 12v wiring for both the driving lights and the power in the van, wired up all the switches etc. 
I have started cutting and replace the ply on the walls and the 2 ends as well, we went and bought the floor vinyl, made a template and cut it, so will be painting around the bottom of the cupboards and walls and will glue it in. I also took the old pop-top skirt to Brissy for a new one to be made, it seems this may push my finish date back as he wasn't sure if he will get to it by Easter, but I should have everything else completed, so we will see.
The wife has picked the inside colours and I have to start thinking about the outside colour/s. Another job is I have to fit the brackets to the awning but I need the pop-top in place to make sure it doesn't rub or hit the brackets. If all stays to plan then it should basically on the road in 2 weeks. Right now I'm about to start making the bed frames/cupboards.
Cheers |
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Post by Mustang on Mar 23, 2015 19:16:22 GMT 10
Whacko the chook, what are you going to do after this one is finished.
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Post by Deleted on Mar 27, 2015 17:14:29 GMT 10
Whacko the chook, what are you going to do after this one is finished. Go travelling  |
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Post by Deleted on Mar 27, 2015 17:35:20 GMT 10
Well cleaning up some of the smaller job's, the beds are made and except for cupboard doors, the rear bed is complete, and the front one will be by early next week, as I have a few things to sort out with the battery and 12v power and cables etc . I have started painting area's inside and will continue to do so next week. The vinyl is glued in place and protected with the cardboard template as I finish off bits and pieces.
The rear bed frame being build, was glad I had kept the old frames as I couldn't remember how they made it in the first place, amazing how much weight it can take for very little timber
This is the front bed and the frame is finished, you may notice the cross members don't go right through as I need to get into the top area and as the fridge is right beside the bed, I cannot put a door in that spot so will cut a section out of the ply top and will add some extra support to sit it back into and will lift the mattress to access the area if needed.
The air bed is just to give you an idea of the size, we will be getting some foam mattresses from Dunlop next month. I have enough ply from the bed tops left over to make doors for under both beds, 3 on the rear bed and 2 on the front, so will have plenty of storage places.
This is what I removed at the very start, I kept it so as to remember how it came apart and size etc
So I was tired of walking around it and decided to do something about it 
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Post by Deleted on Mar 27, 2015 17:39:01 GMT 10
And something I did...  
Cleaned the water tank inside and out, I use bleach on the inside, just remember to give it a very good rinse 3 or 4 times or until you can no longer smell it. I am presently fitting it back into place and will use some of the excess alloy checker plate to make new stone guards for it.
Cheers |
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Post by pisces51 on Mar 27, 2015 20:17:50 GMT 10
Well, that framework ended up looking pretty impressive, ay?!  Great job! What conclusion did you reach about the thickness of the ply covering the frame? Good to see the ceremonial burning of the redundant timber. Nothing better than being able to put all that behind you. Onward and upward, hey?! cheers, Al. |
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Post by Deleted on Mar 28, 2015 6:31:38 GMT 10
Hi Al
oh that morning I burnt the old timber was like turning a corner ! The ply ended up being 7mm as the big green shed in Qld no longer stock 6mm except in marine and I wasn't paying $60+ a sheet. After fitting it to the frame, I reckon 4mm may have been enough and easier to fit ! I had to cut the back bed sheet as there was no way to get it into position and the wife was worried the bed would be weaken because of this.
I also only screwed the sheet in place, haven't glued or stapled it. If the vans weight becomes an issue will look at changing the thickness.
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Post by Mustang on Mar 28, 2015 8:08:49 GMT 10
Cleaned the water tank inside and out, I use bleach on the inside, just remember to give it a very good rinse 3 or 4 times or until you can no longer smell it. I am presently fitting it back into place and will use some of the excess alloy checker plate to make new stone guards for it.
Chjeers Just like our MORTGAGE Burning Ceremony!!!  |
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Post by Deleted on Apr 4, 2015 6:59:10 GMT 10
OK this is the end of the photo's... 
But why.. well there is nothing more atm to show, everything is done and just need to finished of a couple of things and we should be on the road 18/19th April. The beds are painted and have there doors fitted, the battery and all cabling is secured into place, checked and tested and works perfectly. The water tank is fitted along with it's new guard (some of the excess checker plate from the front). We went into Brissy and have picked up the pop top skirt and I also after many days reading and talking to paint stores etc decided on the paint to be used on the pop top and van, this week I will be sanding down the pop top roof for patch and paint and hope to have it back on by the end of the week. We have been to clarks rubber and tried the foam mattress for the van and the wife is happy to use it so we checked the Dunlop website and found there are a number of retailers who sell there products..  But after 2 hrs driving around it seems if it is not a standard single bed, then they are not interested in ordering one in for us.. 
So it looks like we have to deal with clarks rubber for the mattresses.
There are a number of bits and pieces on the van that need to be clean and painted etc but they will get done in between our weekends away, things like the stabilizers, new doors on the cupboards, just small stuff that can be done while we enjoy the van and sort out what we want where.
So the next photo's you will see is when it is all back together and ready to hit the road for the weighbridge.
Cheers |
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Post by pisces51 on Apr 4, 2015 21:13:39 GMT 10
Congratulations on finishing your project "on time and on budget", Lockyer!! Whenever somebody in the future says, "It can't be done!", I will refer them immediately to your thread. Don't stop posting photos just because you think you've finished. We always enjoy seeing people out and about in their vans, enjoying the fruits of all their hard labour. Best wishes for your future travels, and thanks for sharing your story with us so far. cheers, Al. |
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Post by Mustang on Apr 8, 2015 17:05:30 GMT 10
OK this is the end of the photo's...
bugger!!! |
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Post by viscountofmydomain on Apr 9, 2015 8:54:26 GMT 10
The chassis reinforcing is completed and so to the water tank locaters. Hi lockyer I've just found this thread, you've done some great work, I'm interested in how you did your chassis reinforcements, our Viscount chassis is similar to yours. Are you able to please post a pick of a completed reinforcment. Cheers Stu |
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Post by Deleted on Apr 11, 2015 6:56:19 GMT 10
The chassis reinforcing is completed and so to the water tank locaters. Hi lockyer I've just found this thread, you've done some great work, I'm interested in how you did your chassis reinforcements, our Viscount chassis is similar to yours. Are you able to please post a pick of a completed reinforcment. Cheers Stu Hi Stu, what I did was get some 50mm gal angle approx 2.5mm thick , I cut them to fit into the chassis and either pushed or jacked the rails into place and then I drilled and bolted the angle to the main chassis then to the cross member. Will get a pic or2 soon |
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Post by viscountofmydomain on Apr 11, 2015 9:19:45 GMT 10
Hi Lawrence,
Thanks for that, pics would be great.
Stu
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Post by Deleted on Apr 15, 2015 7:40:10 GMT 10
Hi Lawrence, Thanks for that, pics would be great. Stu Hi Stu The forum picture limit has been used up for this month, so if you like PM me an email address and I will email them to you. |
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Post by Deleted on Apr 17, 2015 11:53:53 GMT 10
OK tomorrow we will take "Wichway" out on her maiden voyage, not going to far or for long, just over night. I will get some photos of her set up. Just remember the outside painting is not finished plus a few things like stands etc will be cleaned up in the coming weeks.
This trip is to give us an idea of how we will store our gear in the van and see if anything needs changing or adjusting.
It will be the first time I have tow any caravan more then 20/30klms, I have been practising hooking it up and taking it around our local roads during the week and unhooking, so as to get a feel for it behind the ute. It is almost 5 months to the day from when I brought the van home and the time flew by plus I almost managed to melt our credit card as well lol.
Time to start the fun and adventures
Cheers Lawrence
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Post by tasmillard on Apr 17, 2015 12:18:42 GMT 10
Looking forward to the pics. Funny, I will be in the same position soon, never towed a van and maiden trip will be about discovery etc. Good luck.
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Post by Mustang on Apr 17, 2015 18:39:35 GMT 10
It is almost 5 months to the day from when I brought the van home and the time flew by plus I almost managed to melt our credit card as well lol. Time to start the fun and adventures Cheers Lawrence What only one, (CC) you are not trying! |
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Post by Deleted on Apr 25, 2015 14:34:33 GMT 10
OK lets see if this photo uploading thingy works, the new pop top in place after I had painted the roof section 
And here she is all her glory, some 3 months after she went in, it is time for her to come out into the daylight, it was the first test tow after all repairs and reno's 
I must say it looked so much bigger when I was working on it day and night but now it is out of the shed, it looks so small.
Cheers |
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Post by Deleted on Apr 25, 2015 14:47:34 GMT 10
Well we went away for a test run - only out to Clifton showgrounds as it's approx. a 90min drive and the roads vary from good highway to narrow bumpy back roads, plenty of turns and winds and some climbs and hills. The showgrounds have power and water so I could test out all the connections and look for leaks . It was only one night and we have a list of things that will be changed or added etc
First setup 
With the awning out, we didn't have it up on Saturday as it was to windy but Sunday morning was calm so we quickly put it up to get some pic's and had a look, and found out one of the ropes was way to short but I have some cord here to fix that hic up.
cheers |
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Post by Deleted on Apr 25, 2015 15:03:37 GMT 10
Well we are off to Queen Mary Falls next weekend for a few days, have been finishing off some painting inside the van, plus ordered a few things to relace some of the worn parts inside, We have decide we will be painting the bottom third of the sides of the van the same shade of grey that the awning bag is (hard to see in the photo's) and the rest will be white.
One thing I did learn from our first trip was the van tows 100% better using the load levelling device, a lot of people told me I don't need it and to remove it as it isn't a heavy van but we towed the van approx. halfway out to Clifton and I had already fitted all the connection points to the van and ute and we hooked the bars in and lifted into place. I was so amazed how it went from knowing I had a van behind me to feeling like we were driving without it on.
I will be taking it back to the weighbridge once we have it loaded how we want, we have also decide to look for a S/H canopy for the ute and will carry the chairs/solar panel/tables/BBQ in the back of the ute as it has plenty of pay load available.
So if anyone know of someone in either SE Qld or Nth NSW that has a canopy for sale for a Ford Courier 2005 crew cab tray back please let me know.
Cheers |
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But after 2 hrs driving around it seems if it is not a standard single bed, then they are not interested in ordering one in for us.. 
