Project Camper Connie 2 (mk5 exlwb hi-cube)pic update27/9/09

[Breakdown Biker]

Thanks Andy

I started another thread for the headlight conversion
viewtopic.php?f=13&t=48700

Here's a couple of pics of the progress so far.






I've modified the headlight brackets and bonnet, fitted short mirrors, fitted day-lights,
clear side-repeaters, new number plates, changed the wheel trims and re-painted
the whole van again
I'm just getting the materials together to modify the front grill and I'm planning
to fit a side-step

[noobrider]

Very smart. I particularly like the way you have painted the black round the windows

[Deb]

I particularly like the way you have painted the black round the windows

Me too might pinch that idea

Very nice van, I bet you are proud of it.

Debs

[Breakdown Biker]

I particularly like the way you have painted the black round the windows

Me too might pinch that idea

Very nice van, I bet you are proud of it.

Debs

Thanks for your comments

Yet another idea inspired by the folks on here
tbh I wasn't too sure about it at first, but once the windows were tinted I was well chuffed

Yeh, Debs, I am proud of it, I've had the van for two years, and all my friends & neighbours
have been watching my progress. It's been a labour of love and heaven only knows how many hours I've spent on it
but every now & then I look at a picture of how it was when I got it and get a real sense of achievement.
It's a wee bit rough in places but it dosen't stop me and the Mrs thoroughly enjoying using it

[Breakdown Biker]

Just a wee update as I've been busy working on the wifes and daughters cars
I've renewed the propshaft bearings and I'm still getting a judder, not quite so bad as it was,
but it looks like I'm gonna have to do the clutch
I've had to jump start it a few times recently, so I invested in a new battery
Got a great deal on one of these

It's got excellent cold cranking ability, 5 year guarantee, and only cost 80 quid from these guys
http://www.manbat.co.uk/
I'm now looking at installing a third battery as my van came with a split charge relay, but I didn't use it coz
the leisure battery charge is controlled by the zig unit.
I'm hoping to weld a bracket next to the leisure battery, but will have to fit a heat shield to protect it from the manifold/downpipe.
I've also got some ali chequer plate that I'm gonna fit on the rear bumper,
and a high-level brake light.
I'll take some pics of my progress when I get a chance
Meanwhile here's how she's lookin so far....

[noobrider]

sure looks good breakdown, I figured my judder comes from the thrust bearing on the clutch, shaft bearings seem |OK. Might be something to check

[Breakdown Biker]

sure looks good breakdown, I figured my judder comes from the thrust bearing on the clutch, shaft bearings seem |OK. Might be something to check

My propshaft bearings were totally shot mate , so they would have to be done anyway.
Since I intend keeping the van for quite a long time, I'm just gonna fit a whole new clutch,
but I have to save up me pennies first
The daughters car wasn't too bad, just needed an exhaust, drive-shaft boot, and handbrake sortin.
The wives is a bit more with ball-joints, droplinks, and a rear brake overhaul. Beemer parts cost a fortune.
And the CBR fuel pump, I've been quoted 185 quid
So it might be a while before I can afford a clutch kit for the van

I got the battery tray fabricated today,:D just need some dry weather or a space at work to get it welded on

[misty]

Just a quick one,
we are about to start our conversion, just waiting for the side windows to be done week after next, so i will start with the mushroom vent on the front and a mpk 280x280 roof vent at the back,
my question is how did you stick the bubble insulation to the panels and did you stick the rock wool to that aswell??, thats the sort of insulation we were thinking of doing as kingspan seems hard work and costly (budget) also we will be squirting expanding foam in all the voids we can find,m
misty

[Breakdown Biker]

Hi misty,
Before I insulated the side panels, I sprayed them with underseal and a day or so later it was just a wee bit tacky. The bubble insulation just stayed in place.
The rockwool didn't need attached as I tucked the edges behind any bits of the vans framework then fitted the wooden panel over it. I packed as much as I could in to each space and had a wee bit of a struggle at times getting the panels back on.
I hope this helps.
Good luck with your build and try to post some pics for us

[Breakdown Biker]

When I bought my van, it had a split-charge diode fitted but I didn't use it coz the leisure battery charging is controlled by the zig unit. The starter battery I had been using wasn't the right one and was only a temporary fit. Now that I've invested in a new battery, I decided to use the old one as a backup since all the wiring was already there.
I fabricated a wee shelf and bracket for it, then tacked it on the n/s of the engine bay

'scuse the rough welding, it was really awkward to get to but it's nice and solid
I then made a heat shield for it and connected up the battery and clamped it in place

With that done, I was intending to finally modify the grill under the lights but had another wee job to do first.
I salvaged a wee nudge bar from a body-shop skip and decided that I should figure out how I was gonna fit that
first, just in case it needed any grill mods


The bar is off a Rav4 and is made of stainless


I had to modify the original brackets and drill new mounting holes.
Stainless is hard as hell
and I destroyed a grinder disk and melted several drill bits but I got there in the end


My clear indicators arrived so they were fitted too

By the time I'd done that and messed about wi some black paint, I decided to call it a day
as the light was fading. I like the centre of the grill in black but I'm no sure about the spoiler
Wot d'ya think?
I really should put my fag out before I use the camera

[chopper123]

nice van mate
but christ your chancing it with that battery right next to the manifold
ive seen a battery explode and its not nice
i see you have put a heat shield in place but still a braver man than me

[noobrider]

I like the look. The nudge bar looks really good and I think the black paint is a good look that accentuates the stainless steel bar.

I agree with Chopper though. That battery is a bit too close for my comfort. Is there not space on the left hand side of the engine just under the scuttle? Mine has two battery shelves quite high up and one on either side and taking a much bigger battery than that one

[Breakdown Biker]

nice van mate
but christ your chancing it with that battery right next to the manifold
ive seen a battery explode and its not nice
i see you have put a heat shield in place but still a braver man than me

Thanks bud,
and tbh I think you're right about the position of the battery
It's gonna have to come back out now as I've got my hands on a sweet runnin banana engine and I'll need that space for the air-box
Don't know about braver, maybe just dafter

[Breakdown Biker]

I like the look. The nudge bar looks really good and I think the black paint is a good look that accentuates the stainless steel bar.

I agree with Chopper though. That battery is a bit too close for my comfort. Is there not space on the left hand side of the engine just under the scuttle? Mine has two battery shelves quite high up and one on either side and taking a much bigger battery than that one

Thanks mate, I guess it always takes me a while to get used to a different look.
I love the bar and the slotted part of the grill, still not too sure 'bout the spoiler bit.
Maybe once I've filled the gap at the lights I'll have a better idea.

Like I said to chopper, I'm gonna take that battery out again for the new banana
I'll mess about with it's positioning once the new engine is fitted

[knighty1981]

the trick to drilling through stainless is to use a big powerful drill but only have it spinning really slow... push hard and spin slow...


once you go fast... stainless gets 'polished' by the drill bit and is pretty impossible to drill through !

tiny pilot hole always helps too !