As soon as it started, Jon went on his way and I tidied up. Started putting all the bits back together and fitting the metal engine cover that sits along the bottom of the engine to stop any road debris from being kicked up and damaging things. Started the engine again and realised that the oil light was flashing constantly andit beeped like mad to start with, well by this time I was getting used to disappointment, so rang Jon who was still on his way home and asked if he had any ideas, he didnt, so went and moaned to Jen that we now had another problem and that I was going to scrap the bloody thing ! I went back out and tidied up some more sulking. Meanwhile Jen looked on a few forums and this problem has come up a few times before, most of them had traced the fault back to the alternator, and one of its 2 small wires being damaged, so off came the metal protector underneath the engine again, and I had a look at the alternator, the lower plug with the red wire looked damaged, so I went to pull it off and it almost fell away in my hand, shone a light and used a mirror to see into the plug recess on the back of the alternator and saw that the single pin was bent over, so obviously making no contact at all with the plug, bent the pin back straight, pushed the plug back on and tried starting it again, this time the oil light went out and stayed out :). So well done Jen, for the third time in a couple days you did a great job :) x.
Sunday, 31 May 2009
Engine In !
As soon as it started, Jon went on his way and I tidied up. Started putting all the bits back together and fitting the metal engine cover that sits along the bottom of the engine to stop any road debris from being kicked up and damaging things. Started the engine again and realised that the oil light was flashing constantly andit beeped like mad to start with, well by this time I was getting used to disappointment, so rang Jon who was still on his way home and asked if he had any ideas, he didnt, so went and moaned to Jen that we now had another problem and that I was going to scrap the bloody thing ! I went back out and tidied up some more sulking. Meanwhile Jen looked on a few forums and this problem has come up a few times before, most of them had traced the fault back to the alternator, and one of its 2 small wires being damaged, so off came the metal protector underneath the engine again, and I had a look at the alternator, the lower plug with the red wire looked damaged, so I went to pull it off and it almost fell away in my hand, shone a light and used a mirror to see into the plug recess on the back of the alternator and saw that the single pin was bent over, so obviously making no contact at all with the plug, bent the pin back straight, pushed the plug back on and tried starting it again, this time the oil light went out and stayed out :). So well done Jen, for the third time in a couple days you did a great job :) x.
Thursday, 28 May 2009
Some Better Pics Of Interior & Seat Pads
Today I picked up the last bit of metal for the bed pull out frame, this will be fitted over the wheel arch seat box, and will pull out to make the bed. Once all that is done, I can see for sure how much room I will have for the cupboard and the kitchen unit.
These pics were taken with an ultra wide angle lens, so if it all looks a funny shape thats why :) (thanks to Tammy for lending it to me whilst she is on her holidays !)
The Doorstep on the side door will eventually be finished off with a blue plastic door step from Volkswagen, I believe they are about £35.
Also have to mention the engine, the new engine is in now, and connected up, just need to put the fluids in and the battery, see if it starts and runs ok, then replace the bottom engine cover and pollen filter that goes above the battery. So more to come tomorrow (actually later today), a big thanks to Jon for all his hard work getting the engine sorted, lots of new parts, a big thanks to Verns Autoparts in Tredworth for those, so check back later and see if the engine was a goodun or not :) (PLEEEEEEEEEASE all keep your fingers crossed for me, if I have to I will get another engine, but please dont let me have to !) :)
Tuesday, 26 May 2009
Engine Started and Sneak Preview of Seating Cushions...
Jon arrived about 2pm, and we got stuck in, I was just helping doing the odd bits and fetching carrying and coffee runs, I just dont have the memory to remember where everything goes anymore. Anyway all went pretty well, nothing too hard to report, until the engine was all disconnected and sitting on the trolley jack supported by the engine hoist, there are 2 ways to bring the engine out, from the front with the radiator removed etc, and from underneath, but you then have the problem of lifting the van off and over, so that way is best done if you have used of a ramp, either way the radiator has to come out to allow access to all the bits and pieces behind it. Anyway, Jon was loosening it from the gearbox, and it suddenly dropped forward and ended up wedged on its front, managed to lift it back up with the hoist and trolley jack, and after a lot of wiggling and jiggling it came out around 6pm tonight, so 3-4 hrs to get it out, not too bad :) Its suspended on the engine hoist in the carport now next to the new engine, Jon will be back in the morning to swap all the bits over and replace the clutch and timing belt with pulleys, whilst I am working, then hopefully it will be almost ready to put back in by the time I get home to help again.
Engine In Place, Front Panel & Radiator Removed
Went to Focus on my way back home and bought the Aluminium strip to finish off the back of the laminate flooring, wasnt hard to fit, used chrome collets and steel screws, finished it off nicely :)
Well here it is, the sneak preview as promised, delivered quicker than promised, havent had a chance to make the seat carcasses yet ! :) Martin, will email you the details of the company, just havent had time to reply yet :) This seating is made from 4" fire retardent foam, covered in blue leatherette, I wasnt sure about the colour when I first saw it in the box, but when I put it in the van, and pictured it with similar coloured curtains, I think they will do fine :) Obviously better photos to follow when the seating has been installed, have to pick up the last of the metal tomorrow so that the metal bed pull out frame can be finished, then just need to build them up and bolt them in :)
Thats it for an update today, as well as what I just said, have to go back to Vern's tomorrow and get a new battery for it, the old one flattened and wont take a full charge anymore, so may as well replace, Im thinking nearly everything has been replaced now !
Talking of which, when we were taking the engine out today, Jon thinks that the starter motor, front exchaust down pipe, turbo, and alternator have all been replaced in the last year or so, so thats really good news, when its all done I should have a van to last ! :)
Monday, 25 May 2009
Important Safety Message and Flooring...
Next job was laying the foam underlay, this is when my 'accident' happened, on the first cut, which was good in a way, made me take notice and pay attention to what I was doing ! I layed the first strip then started laying the laminate.
This wasn't actually as hard as I thought it was going to be, thanks to Mike who lent me his laminate flooring fitting kit, I did quickly watch some videos on You Tube first to pick up a few pointers, then got stuck in. It was pretty easy to do the cut outs, I used a Dewalt 18v Jigsaw, it went through it easily, and luckily barely made a mistake the whole time. One of the first pieces I laid down, the one looking from the back of the camper, going round the right hand or drivers side wheel arch it didnt seem to click into place properly, I carried on but once I'd gotten towards the end and realised that that first one hadnt actually worked properly, I shifted the flooring over slightly and took the first row back up again and redid it, looking more closely at the strip of laminate, I found it hadnt been machined properly, and the very end was discoloured, once i'd cut the new piece out and put the row back in, it all sat down properly and clicked together positively, I'm glad I went back and did it as even though that piece would have been underneath the seating, it would have always been in my mind.
So that was it for today, and it has really made a difference to the look inside, its all coming together, to finish off the flooring across the back door, Focus do an aluminium angle strip that I am going to get and fix down to hide the end of the wood, and the side door opening, I will order a plastic door step cover from Volkswagen, they do it in blue, this will finish off the step and has a lip that will finish off the bare wood from the cut around the step, pictures to come when done :) This is how it looked today when I finished, I was a little bit pleased :P.
Sunday, 24 May 2009
Wow what a day ! :)
Second job of the day was to finally get the insulating done, thanks to Martin's guide, I went and bought a sheet of 50mm Kingspan and a sheet of 25mm Kingspan, both were 8ftx4ft, the 50mm was to go in the lower half of the van walls where the cavity is wider, and the 25mm was for the top half. Its very easy to cut with a hand saw, and the following pictures speak for themselves. I used Hard As Nails glue to stick them to the walls, in Martin's guide he taped up all the gaps that were left, but on doing it, I decided this wasn't nescessary in my case, so left it as you see in the pics.
Saturday, 23 May 2009
The Awning
Metal Bed Frame
Friday, 22 May 2009
Lots of bits turning up .....
The battery has turned up, went for a Lucas 120 amp leisure battery in the end, I was looking at the 180 amp ones, but when I saw the physical size of the battery was around half a meter long, I thought it was going to be a tad too big for where it was going.
Also got the 12v Wii lead for when we take the Wii away !
Rich told me to get the garage consumer unit from screwfix for the electric hookup, at £38, before I went ahead I had a quick look round ebay and found one that had a best offer on it, new stock, it was at £16.99 buy now which was way cheaper anyway, the seller settled for £15 plus postage, so looking at around half the price screwfix wanted, so am pleased about that. Should be nice and safe now.
Got the blue carpet I needed to finish the interior, only I didnt, the auction said Bright Blue, unfortunately its not as bright as the carpet I have already used, its quite a bit darker, so am going to have to order some more from the original seller, he didnt have any when I looked earlier in the week, should have waited I guess and seen if he listed some, but on the auction it looked just the same. Not to worry. I can use the darker carpet to line the wooden boards that will top the seats.
Talking of the seats, have decided to make the fixed seat out of wood, and the converting seat from a wooden base with a metal frame top and a metal pull out frame to convert to a bed. Picked up most of the metal today, but the smaller size i needed to fit inside the main stuff, they ordered round tubing instead of square, so have to pick that up wednesday, so cutting it fine, but still doable. Bought the wood from B&Q earlier, they are doing a special deal on some, about £3 off per length, bought enough for both seats, and then 4 extra lengths in case i decide to build the tall cupboard myself.
Oh I fixed the awning rail to the front of the carport tonight to see what the awning was like, its very good and gives a good amount of coverage, was pretty big on the carport, will be very big for the van, give plenty of shelter or shade, only problem was I fixed it too low so the leg rest point has nothing to sit against, will fix it higher tomorrow. Will try and get the van rail fixed on tomorrow too, looking forward to seeing what it looks like on that.
Thats all for now, hopefully be a few pics of my progress over the weekend, so make sure you come back and check :).
Tuesday, 19 May 2009
Getting it all together ......
Nice isnt it :)
Now all I need to do is make a decision on how Im going to build the seating structure, I want it to work independantly of the rest of the camper, not rely on the bed having to rest on other bits of furniture to form the bed, so we went and had a look around some motor homes yesterday and they use a mix of wooden and metal framed structures. None were really what we wanted though, so when we got back, Jen thought of a way we could do it with metal square tubing. I worked out all the details, how much tubing we would need etc and exactly how it would all fit together, rang Andy and asked him if he would be prepared to weld it all up, he agreed bless him ! :), then Jen rang a local metal works firm this morning, all the bits and lengths cut to size ready to weld, came to £150, now this would be great, very strong, and give maximum space inside the seating for storage, but £150 is another big dent in the money, and we already don't have enough to finish it all off, so may have to look for a cheaper alternative, Ihave designed a wooden structure that is based on a drawer system, where a big drawer pulls out of the main seat which has a double top to it that will foldout over the "drawer" to form a 6ft x 4ft bed, could probably build this for about half the price and it would be lighter than all metal which would save a bit of fuel, so is likely to be the way we go, although it would mean less storage space as the wood frame would be bulkier.
Will try and post either a plan of what I want to do or the finished pic of the structure to show you what i mean.
Bought the laminate flooring on the way home too, 2 packs = to 5 m2, which should be more than enough, maple effect to match the worktop, need to find matching units now for the cupboard and kitchen unit.
Bought a strip of awning rail whilst we were at the motor home shop, need to get another for the camper, going to put this one on the front of the carport to give Jon a bit of shelter when he fits the engine out on the drive. One 12ft strip cost £14.40.
Thats about it for now, waiting for the ordered bits to come, and need to sort out some wire and electric sockets etc and a few more bits and pieces, got to be really careful with the money so will look for the best deal.
Need a sink/hob too, and actually saw a nice one on the T4 Forums, but got there a tad late as it looks like it has already been sold, shame because it looked really nice and would have fitted my kitchen unit just right.
Check back soon, as things are going to be moving along quite quickly now, so lots of pics to come ! :)
Sunday, 17 May 2009
Awning....
Also managed to find a work top to go on the sink and hob unit, decided on Beech coloured laminate flooring, and have found a worktop to match that, got a really good deal on that too, in Focus, they had 4 of these worktops, discontinued, selling them off for £10 each for a 3 meter length, obviously wont need all that but for £10 when they are around £90 normally, I wasnt going to say no :).
Friday, 8 May 2009
Yay !
So Yay ! I have an engine finally :)
Just have to get a cam belt kit and a clutch kit and some oil and a filter, and we can start fitting it.
FINALLY I have some motivation back to crack on with the conversion :). Its been such a downer having it sat on the drive broken. Be great to start using it again, once the engine is in, it has to be MOT'd, and taxed, so a way to go yet, but at least things are moving along again. :)