Caravelle to Camper self build.

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Re: Caravelle to Camper self build.

Postby mattrsa » 25 Jun 2011, 09:34

Thanks very much for the reply.

I think you are right about taking your time. I am worried as I do tend to lose interest and just start cutting and end up f@%king it up.

Got a jigsaw already so will go to b n q and invest in some good blades.
I only have four week till I'm off to europe for 5 weeks so I really need to get something sorted asap.

Will keep you updated on the progress and will keep following this thread
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Re: Caravelle to Camper self build.

Postby hicksy » 25 Jun 2011, 09:42

Ok, all the pictures are back up now! Next install later, Ive been busy!
See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby Threescoops » 25 Jun 2011, 11:24

hi

loving this....keeping an eye on all ur tips as we are going to do a similar thing to ours when we get back off hol and once it has had mot & back box of exhaust has been sorted (obviously before the mot!!) my dad pretty handy with wood and other half with electrics, ill just pick all the material and my mum guna sew it all - a family affair lol

ur doing a fab job loving the things uve done so far...keep it up :)

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Re: Caravelle to Camper self build.

Postby hicksy » 25 Jun 2011, 11:58

Thanks Nikki. I like to post my progress as I have always loved readers rides-type threads and build threads so Im just paying back really! I hope people do get tips too, as again, reading otheres project has helped me get the motivation to do this!

Right, so what happened last weekend?

We had a fairly busy one on the saturday morning as we had to pop out and get a fathers day pressie but as it turned out my Dad came by in the afternoon to help out! Now this is a pretty rare occurrence as he has never really understood my VW addiction, but, as has happened before, Mum was at work, and he was bored, so he offered his help.

To that end I put him straight to work refitting the door cards and fitting the Space-Mat type insulation in all the cavities. Heres a pic of him fitting the rear hatch panel. He could have worked from the inside, but Dads know better dont they! Couldnt resist this picture!

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Also, my pal Jordan came over and this guy is a Vinyl and design genius. He has done plenty of stickers for me and my friends before and I have forwarded his business on to many others. Anyway, I wanted to blank out the rear drivers side corner of the van where the rear wardrode is. I had thought for a while on how to do this cost effectively and neatly so came up with this....

Work in progress, with my dad spectating...

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Et voila!

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Nice eh?! It may not be a perfect match but I am so happy with it and it serves its purpose perfectly. Once it has a few surfing stikers and show stickers in the window it should blend right in!


And at the rear....

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby hicksy » 25 Jun 2011, 12:12

Whilst my dad was doing the door cards I was messing around with the long-panel door card. I could have quite easily used the original and cut a big hole in it for the fridge exhaust flue but I I dont like doing stuff like that with original equipment (despite this van now being far from original)

So for £3 a pop I bought some hard board from wickes (my fave!) and got cracking. I used the original card as a template, and I also used the original panel pins in order to keep the cards in place.

First one down

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and mocked up

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other side cut, holes drilled and mocked up. I then glued the the two together using my BFOB as weight. (note the cut out for the fridge)

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I then packed out the cavity with the insulation and used my left over silver tape to seal the ends. The space left is for the exhaust flue to be cut out the long panel. The card was then popped back into place.

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby hicksy » 25 Jun 2011, 12:34

Now the door cards and insulation are in I can start permanently mounting the units in that I have finished. The first one to go in for good is the rear wardrobe unit. But before it did I fitted the shelfs for clothes, and finished the rear of the unit that will have shelfs for things like a fuel can, breakdown kit etc. I also trimmed all of the cut edges with the iron on beech effect trim.

Edges held in place with tape and ready to iron..

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Hot hot!

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And excess trimmed with new sharp blades

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And heres the finshed article. Note the finished rear shelfs.

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And permanently in place. Here you can see the inner shelfs and the nice blu tint the vinyl is giving too!

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby y30man5 » 25 Jun 2011, 18:02

I am lovin this post!... It's really making me want to get on with my interior!

Unfortunately, my interior only exists as a small foamboard/card model (to scale - cos I'm a geek! :) ), however, last week I did strip and zinc primer my floor, and wire in my leisure battery (slightly smaller than yours!), so at least a start has been made. I'm gonna start my own thread when I get started properly.

Anyways, keep up the good work! Looks great!
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Re: Caravelle to Camper self build.

Postby Threescoops » 25 Jun 2011, 19:53

wow - impressive! the unit looks brilliant - an old teacher of mine used to say slowly slowly catchy monkey....certainly seems to be working here taking time and paying attention to detail!

shame you dont live round the corner or id be comissioning you to do mine hehe! :)
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Re: Caravelle to Camper self build.

Postby hicksy » 25 Jun 2011, 20:33

Thanks guys! I really appreciate the kind words.

Yeomans, Using the template and model method sounds pretty good. I did a few rough sketches at first as I knew in my head what I wanted and looked at loads of interiors at shows, but to be honest It has just evolved! I think that has come down to the fact I used parts froma second hand interior, and as its all on a budget!

Thanks too Nikki, and as for doing somebody elses?! I have already vowed not to do one of these again, it has taken over all my free time for two months already, and with work right now, I dont have much free time!

We are house/pet sitting for my folks this weekend but I have been doing bits on the interior still, so there will be another update shortly, stay tuned!
See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby Threescoops » 25 Jun 2011, 20:52

lol fair enough...however when you look at 2 months compared to the years of enjoyment to come im sure you will think it was all worth it in the end!!!
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Re: Caravelle to Camper self build.

Postby hicksy » 26 Jun 2011, 22:23

Just a quick one today.

I mounted the cupboard door! My first, and I was very nervous in case I screwed it up but it fit! Next thing to do is get hold of a 19mm hole cutter to drill the hole for the button push/catch.

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Then I worked on the panel to house all the electronics. I had a 240v plug socket to fit, mt 12v-240v inverter, and my switch board.

Heres the panel, withe the holes cut and bits temporarily mounted. The inverter cannot be conventionally screwed in like the 240v front,so I had to make a perfect size hole, trim it with the iron on edging, the poke it through to give the appearance of a flush fit. To support the unit I made a shelf with cut offs.

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To conceal all the electronics and still have them accesible when I needed to get to them, I made a panel from white faced hardboard that i had left over from some other project, backed it with 2x1 and trial fitted it. It works well, and I will screw it in with only 4 screws to save any extra effort when it comes to taking it out!

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby hicksy » 17 Jul 2011, 21:48

Wow, I have a lot to catch up on this I think. Last update 26th June!

First off, I made doors for the rear unit and hung them. I really enjoyed making these and although it was a hard task to get them all sitting straight I achieved the look I was after, clean and flush. I was actually inspired by a gold caravelle I saw at the volksworld show this year and the interior in that. Turns out its in the Camper and Bus magazine this mointh I think.

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Then I made the drop down grill door.............

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Works like this.

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I then hung a cieling in the cupboard ready for the hanger rail.

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby hicksy » 17 Jul 2011, 21:59

Since buying the second hand interior that kick started this build the bed/seat cushions have always had a funky, doggy smell. I have been airing them every time I have worked on the van but the smell still lingered, so on a nice sunny sunday I decided to wash them. I drenched them all with the hose then got physical...........

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Check out the funky water pouring out of it!

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Whist I was stomping, my Vinyl man, Jordan popped by (he took the pics!). He had brough with him my replacement fridge front. The fridge that came with the second hand interior had a faux wood fablon front. I ripped that off and was left with the panel. I originally asked Jordan to recover this panel but he said he could do one better.

He re-made the entire panel and trimmed it in a matching blue to my van. The same colour as he had previously vinyled the windows.

Old and new next to each other...

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And mocked up in place....

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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Re: Caravelle to Camper self build.

Postby norfolkbcs » 17 Jul 2011, 22:19

That is looking so good.

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Re: Caravelle to Camper self build.

Postby hicksy » 17 Jul 2011, 22:27

Another job I had been dreading was putting the push button catches in my new doors. I was dreading it beacuse if I fluffed it up, I was buying more wood. Turns out, I rushed the first one, on the biggest door, but I managed to save it and I learnt my lesson. They got better after that!

So how do you fit them?

Mock up the inner catch plate where the door shuts and accurately guess-timate where the centre of the push button catch will be. This is where you will make you first hole. Then measure twice and cut once (or drill in my case).

Cover both sides of the panel you want to drill with masking tape. It aids marking up and prevents the panel blowing out when you drill through.

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Then drill. I first made an accurate pilot hole, then used a 19mm hole cutting bit. I actually had to enlarge the hole slightly with a file to accept the trim (remember to keep the tape on for this bit. Then gently tap in the front trim with a rubber mallet.

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Filp the panel over and place in the rest of the catch.

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Should end up looking like this...

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And this..

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Finshed kitchen cupboard...

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And wardrobe, which I am very happy with...

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See the resto of Frank, my bug, here: http://www.volkszone.com/VZi/showthread.php?t=666711

See My Caravelle to Camper self build here: viewtopic.php?f=40&t=85063
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