CandyVan conversion journey

[drinfinity]

Two days off for an early Christmas present from the parents, who bought me two days ramp hire at East Lancashire Vehicle Storage Solutions .

It was a real pleasure to work on a new van, and the sliding jack built in made it really easy to lower and lift the fuel and water tanks. Much better than crawling under in the road like last time!

First job was fitting the fuel line. Thanks to the forum, I learned about the new fitting on top of the fuel sender, so I just had to drop the tank far enough to snip the end off, and hook up the push-fit connector. The pipe then clipped into the existing VW routing, and over to the driver’s side.

 

[drinfinity]

Next job was the heater. 2kw Vevor under the driver’s step. It came with soft green fuel line, but I used some hard white instead. Mounted to existing holes in the chassis with Rivnuts. Pump mounted on the heater mounting plate so the line runs uphill to the heater.

The exhaust muffler was exactly the same diameter as the pipe, so I had to get some copper pipe to be a sleeve inside. I need to extend the exhaust tail a bit to properly clear the exit.

 

[drinfinity]

Next up was the water tank. I am using the skirt tank from Caktanks. I ordered it with the filler at the front, so they sent it with filler at the back. They took it back, and refitted it at the front, but too high so it fouled on the chassis. They took it back again and finally put it in the right place.

I put some primer on the brackets (which should have been done by the manufacturer) and figured out where to put the hooks and drill an extra hole. The instructions provided are rubbish. Unfortunately Caktanks are the only company that makes a tank that goes here, and they are a shambles.

 

[drinfinity]

Pipe routing. There was a grommet behind the tank that led through a second hole to the inside of the van, which took the supply and waste pipes and level gauge cable. I routed the fill pipe up into the engine bay where there is a space to put the inlet without going through the van skin.

 

[Jim Rey]

Under seat electric installation underway. Hoping to make some progress with a week off work. Spent a while cursing Pop Tops fitting. Their factory is as messy as their website, and my van is covered in now-rusty jigsaw swarf. It cleans off, one spot at a time.

View attachment 176953

It was for fear of this I never did get anyone to fit a pop-top on my campervan

 

[drinfinity]

Wired the heater up this morning, and after three goes at priming there was a puff of white smoke, and it fired up!

 

[drinfinity]

Kiravans seat panel fitted, which gives a flat base for the outlet vent, neater than the OEM panel.

 

[drinfinity]

Work underway on the floor now. The seat rails added some complexity. 15mm ply (left over from the lifting bed base) glued in the spaces between ribs. 9mm insulation board glued on the ribs.

The floor is 18mm Ultralight ply/XPS sandwich, with another 5mm ply layer on top, and will have 2mm Altro over it. To fit the along rails, I had to rebate a channel, and plane down some of the packing where the van floor isn’t flat. The B pillars had to be trimmed at the bottom.

Next up will be the scribing to fit wheelarches and step.

 

[drinfinity]

Floor panels cut now. Since they are so thick, the angles at the bases of the pillars and wheelarches all had to be cut in. I will be happy to see this all glued together and covered by the vinyl.

 

[drinfinity]

Floor done now. So many layers, levels and bevels to get to a flat plane. Only front and rear edge trim and rear threshold to do.

Caravelle step is in, and the light works. I think it needs a bit of packing underneath.

 

[drinfinity]

Water filler added under the bonnet. There is an M6 tapped hole on the van already to take the bracket I made. The pipe goes down to a skirt tank.

I might add one of those Hozelock style adapters to the cap later.

 

[drinfinity]

Ply lining panel made and carpetted, insulation in, lamp lit. The front edge will be under a Vanshades Splashback which is on order. Combination of original VW clips, and some longer ones around the wheel arch. They are more secure than the hidden clips I feel, and will be inside the wardrobe.

 

[drinfinity]

Last panel trimmed and screwed on. Insulated behind, and the water, waste, gas and 12v for the kitchen fixed. All the work is hidden away now, and it’s time to build furniture!

 

[TeeCeeJay]

Looking good. Building your own furniture or constructing a kit?

 

[drinfinity]

Looking good. Building your own furniture or constructing a kit?

Building my own from Garnica Ultralight.

 

[drinfinity]

Vanshades splashback, printed with our own design (to reveal later when the paper comes off).

Started the kitchen build. I had to set part of one panel back behind the fridge, to gain the last few millimetres so the fridge will clear the sliding bed. The panels are cut and scribed in, and the front edge of the 18mm Garnica routed and inset with 9mm poplar ply. Just offered up now to check it all fits.

 

[drinfinity]

First cabinet assembly

 

[drinfinity]

Wardrobe panels offered up for size. Clears the sliding bed by just enough.

 

[drinfinity]

Cadac Dual locker installed, with space for two spare bottles below and a dropout vent. I installed a deck hatch (Amazon) to get to the valve. There will be a hatch in the floor of the wardrobe to access from the inside, and for changing bottles. Only just enough clearance, but it will give me a long space accessible from the back for camping chairs alongside the wheelarch.

 

[drinfinity]

Lots of tinkering in the cellar, and after the delivery of a Tambourline oak veneer door I have my wardrobe built. Weeks of fiddling and scribing and all the flat pack is made and assembled. 30 minutes later it’s finally in the van.

I’ve cut up a 125mm duct which fits around the spiral, so I don’t get anything wedged in it. Push to open draw runners installed. Kitchen fitting next.