Dai Syncro's interior build (with photos)

[jes*b]

Good work , how big is your bag press ?

[uniB]

Humm, not sure - it's about 2.5m x 1.5m I think. Big enough to be a right pain when it's developed a small hole and you're trying to find out where!

Good work , how big is your bag press ?

[uniB]

First major task that's been keeping me busy this bank holiday weekend (no beer gardens and lounging about for me!), lining out with carpet (non stretchy stuff from Mega Van Mats). I'm constantly surprised at how rough and ready original conversions were - this Reimo conversion was pretty simple inside - the wood edging around the roof opening looks like it was built from pallets and panels that lined the van were basic, covering all the original van curves. So, I set to work adding some definition back in, adding some new panels, creating an art installation whilst I was at it



And here are some not very informative pics of how it's looking...







Seat bases still to do - need to let my knees recover from 3 days of crawling about first

[Plasticman]

haha, see im not the only one to be creative,yes i think builds were often to a price and std that was acceptable in its day,
nice to see it being done right, tis the work of the devil though and you could balance plates on the sticks like a circus act
mm

[Dai]

Looking great Dav! I like the relief visable through the carpeting its refreshing to see the shape of the van after 10 years of it beeing hiden behind hardboard panels

[waltraud]

That's a proper job! Nice work and good to see attention to detail.

[Dai]

Come on Dav,Show us how it's progressing

[poshbuggers]

Nice setup Dai.

Your design looks like a variation (with improvements) of the classic Reimo Jolly interior I have just fitted in my Syncro Hightop.

As mine is an ex-Ambulance it was lined with cleanable GRP textured side panels - front to back on the non-slider side and floor to the tintop roofline. I have lined these off the van in the same gear as you are using. I'll do the hightop later.

Nice to see you re still innovating in your van. It's unique and the interior will only add to it.

[uniB]

I finally got round to getting a few photos

It's all coming together nicely and all the (hundreds!) of hours put into might actually end up being worth it! Sorry if you were hoping to see the van at Camper Jam – so were we but it turned out to be too tight a deadline

So the main cupboards in place showing the side hatch which allows the cupboards space to be accessed from the inside and outside. Stainless steel strips which were a joy to make



Back cupboard in place with space under the little cupboard for the Zig unit. Edging's on the work surface, that's been veneers this weekend – only one painful wenge splinter so far!



The stainless steel feature continues to the back - top cupboard panel needs final finishing, sanding and lacquering at this point...



The platform for the bed is a little higher than normal, this is because of Dai's adjustment to the bed hinges which were needed to accommodate the LPG tank. This section was going to hinge originally but I've decided it'll be too big so it'll now just be removable to gain better access to the engine, and it'll have drawers in it, which still need making. Obviously the 'wardrobe' will have side panels!



Another one showing the curvey cupboard bits



I have somemore pics of the laminting of the curvey bits and the curved lamination of the top locker, but this post is probably getting a little long so I'll post those later.

[Dai]

Wow this is looking Good Dav,
im getting giddy now, i can see the wait is going to be worth it,top work mate!!!

[Fabzzz]

Wow this is looking Good Dav,
im getting giddy now, i can see the wait is going to be worth it,top work mate!!!

it does look "pooh" hot ! cant wait to see the finish article ! Dai's Boudoir

[jes*b]

Gonna take some keeping clean - Paul will need to be banned I fear. Top drawer work lovely drop of carpentry. Don't think your gonna have space for those water jerry's Dai

[uniB]

Dai's not told you yet but he's giving up dirty jerry cans and waffle boards and joining The Caravan Club of Great Britain

Gonna take some keeping clean - Paul will need to be banned I fear. Top drawer work lovely drop of carpentry. Don't think your gonna have space for those water jerry's Dai

[uniB]

Few pics of the making of some of the curvy bits.

I started out with some 22mm CNC cut pieces which I glued together to make the former...



The curvy bits are made with two pieces of flexible ply, glued and then stuck inthe vacuum bag. In theory this pushes the ply down onto the former - in practice the curves were a bit tight and the first one went wrong So for the second attempt I added a bit of help by screwing a piece of wood across the tight curve to hold it in place - this nearly worked! By the 3rd go it was pretty dandy.



They then go back into the press to have the outer veneer of maple stuck on - no pics of that though.

For the top locker I needed a huge former so I made that out of polystyrene block, ended up pretty big and only just fits in the vacuum bag. Thankfully worked first time...



And as I was planing up some maple the other day I thought I'd take a picture just for the tool porn lovers out there...

[max.karisma]

Wow! its looking great Dai . . . attention to detail is 'spot on'! Can't wait to see it in the flesh!
Hope all goes well for the weekend and you enjoy your two days of van hugging (sorry repair work)