Hi from another converter

[xjrfast]

Hi all

What a good forum you have here

I bought a LWB Hi-top mk7 ex-network rail van that me and the Mrs have been converting. Started it in July this year and its approx 80% complete. Will post some pics on here at some point. The hardest thing so far was taking all the clark stuff out. They certainly know how to do a conversion that lasts.

Work done so far

Strip out all network rail stuff
Insulate walls and ceiling
fit two roof lights
re-do the elecs including removing the battery saver and replacing it with VSR
Installed 240 hook-up and MCB's
Install battery charger
Fitted Kitchen and 3 way fridge
Fitted shower tray
installed inboard water tank
Installed a Gas water heater
Moved the Diesel heater position
Built framework for seats
Built overhead lockers
Build cabinet for Microwave
Fitted rear windows ( in doors)


I think thats it. Still lots of bits and pieces to do but we have hot and cold water and working hob

Have read with great interest some of the posts here and picked up some good ideas too

Cheers all

Phil

[xjrfast]

Here is the progress so far

Got the van end july 2012 and due to the insurance only covering it for 5 seat, 3 of them had to come out straight away



then it was taking out the back wall along with brackets and wheel arch covers etc


then the microwave, wash basin and boiler had to come out


then the ceiling came out to allow insulation to be fitted


and the insulation in, we used 50mm board for the ceiling due to it being easier than rockwall. We stuck it up with expanding foam


Next the very nervous task of cutting a hole in the roof to fit a roof vent. Measured about 10 times before attacking it



roof vent fitted, which was awkward because of the ribs on the roof. Its now nov and after the wettest summer ever there are no leaks yet


Now brave, we fitted the second vent. Also not leaking yet

Then it was a case of sorting out the electrics as many of the original wiring either wasnt needed or was the wrong size


Then it on with removing the panelling and insulating the walls. We opted for rockwall for the walls mainly down to cost as the board was very expensive


At the same time as putting the insulation in holes were sawn in the side of the van for the electric hook up, water filler and the Carver water heater


next it was onto the kitchen. Many hours were spent doing this as we kept changing the height etc and getting the fridge fitted. Photo below show the almost complete kitchen.


then the gas (forgot to mention the gas pipe was run to the carver water heater before insulating


Next the diesel heater had to be moved as it was in the way but we wanted to keep it as review were good for the heater


Then the inboard water tank was put in


Next was the bit I wasn't looking forward to. Building the overhead lockers. After a great deal of thinking I decided on a plan that would be about the right size and strong enough. Not taken pics of the complete with fronts but they are done.


Ill put the rest of the pics on another page before this one gets too big

[xjrfast]

It was then time to start the seating which is not yet complete as I had to do more work to the pipework etc, and fitting tops to the seating would have made it more difficult
Note the slats are not attached , hence them being wonly


I then started the bathroom


the next few pics show the work done last week to the bathroom. Needs some more silicone and a door and then it will be complete. Tested shower the other day and there is plenty of pressure and nice and hot from the carver water heater. Very please




One thing I forgot to mention was we decided to fit rear windows in the doors. We bought them as a kit which comes with the adhesives and primers etc. The next two pics show the before and after



I have load more pics of the various stages of the build so far. And I have some schematics and stuff I have drawn if anyone wants any ideas.

Oh and one last pic for now. I fitted a reversing camera which I got from ebay, It was new and very cheap. We were amazed at the quality of it ,


will update when we have done some more. Just looking at foam and material for the cushions now

[Northwest2go]

I know exactly what you mean about constantly measuring before cutting out the hole for the roof vent. I was the same. Measured, measured and measured again!! when I did that I measured once again!
Once that jig saw has started, theres no going back!!
I was lucky to get one of my electrician customers to fit my 240 hook up, dis board and electrics.
My wife is currently cursing over the covers she is making to fit over the memory foam mattress I cut up for the seating/bed.

[priesty]

nice work gunna look smart

[xjrfast]

Todays work was to fit the seatbelts to the rear facing passenger seats After a lot of deliberating it was decided to use some box section to span the van and bolt each end. It was either that or remove the fuel tank to get access to where they would bolt.
Took a few pics along the way


and finally the belts in an attached. Just need to finish the seats now and wait for the foam to be delivered

and a close up

[AeroNautiCal]

Very, very nice!

Are you going to insulate the floor?

[BigMonty]

Great work. Keep the pics coming

[xjrfast]

Very, very nice!

Are you going to insulate the floor?

Hi AeroNautical, Thanks - Due to my height 6'3 we don't want to limit headroom anymore, we are going to use some thin , laminate underlay foam stuff which is only about 3mm under vinyl . Hopefully it should be OK as we are stopping the heat escaping everywhere else. We will have the option to fit it later if we find that it is need.

[xjrfast]

Great work. Keep the pics coming

Cheers BigMonty will do

[xjrfast]

nice work gunna look smart

Thanks preisty , we hope it will

[ake]

Nice work, but the hose for your gas bottle should be connected to the copper pipe using a nipple fitting, not just shoved over the copper, your gas bottle should be strapped in as well.

[xjrfast]

Nice work, but the hose for your gas bottle should be connected to the copper pipe using a nipple fitting, not just shoved over the copper, your gas bottle should be strapped in as well.

Cheers for that Ake, I knew about strapping the bottle and ordered a proper retaining kit (that I now cant find lol) but didnt know about the nipple. I try to pick one up on-line.

Thanks again

[ake]

Do you have vent holes in the floor in the bottle storage area? They are to allow any leaking gas to escape? LPG is heavier than air and gathers at low level, hence why you need drop vents in the floor

[xjrfast]

Do you have vent holes in the floor in the bottle storage area? They are to allow any leaking gas to escape? LPG is heavier than air and gathers at low level, hence why you need drop vents in the floor

I have got to drop outs to fit but not fitted them yet. Going to put one under the fridge and one in the gas locker.

Cheers