Jim's LWB 4motion Build

[jimthevan]

Well I thought it was about time I put a build log together after gaining so much info on here I thought I would share my experiences......

So here is my 2016 LWB 4motion 140 in Indium Grey as I brought it from a lovely guy who was a carpenter in Inverness:




I wont bore you with the usual strip out and insulation pics so after removing the bulkhead a good clean, sound deadning, thermal liner, insulation, it was onto the rear windows..



I wanted to fit the pop top myself but only one company would supply me the kit - Streamline - and this worked out just as expensive as getting one fitted.
After much deliberation I decided to go with Skyline pop tops - the standard version as I think it looks better than the Aurora model. Moon rock canvass.

Got Simon from Sunset Campers Vw Camper Hire Cornwall | Skyline Poptops | Sunset Campers Lanivet near Wadebridge in Cornwall to fit it and I must say he did a fantastic job and i'm very picky!



Next job was to install a 6mm ply frame to take the LED light strips before carpeting and side windows going in, covering the screw heads in the pop top framework at the same time:



This took a long time to scribe accurately into the van profile. I didn't get a pic but I then cut slots for the aluminium channels to sit in once carpeted.

I have kept some templates if anyone needs some.

Thanks to

Deaky​

for the inspiration:

Deaky’s Kombi to Camper journey

Could you try the Ring RSCDC30? Here are the basic specs: Yes the Ring will work, it can cope with a solar input of 50volts. The only problem is it's mahoosive and I don't think I have space for it under the seat. :(

www.t6forum.com

​

 

[jimthevan]

Then onto fitting the side windows and lining:

Covering up the large vents on the D pillar with hardboard and ali tape:



Now onto more cutting of holes in my nice van!





Father-in-law doing a great job of fettling the cutouts after i used a nibbler





Carpet lining before fitting the J-trim







Really happy with the result : )



Unfortunately the sliding window is leaking from the end cap on the drainage channel : ( - waiting for a response from camperglass.







Next job is to fit some roof rails to the pop top:

 

[Bav]

Nice work Jim - is this something you've tackled previously?

That trip from St Agnes to Inverness and back must have been an epic journey in itself!

 

[jimthevan]

Nice work Jim - is this something you've tackled previously?

That trip from St Agnes to Inverness and back must have been an epic journey in itself!

Cheers bud

yeah bit of a mission but had friends up that way so good excuse to say hi. First 2 sunset shots are from on the Cairngorms on the way home - epic scenery - hopefully going back next year in the finished conversion : )

Only dabbled on a few bits on my old T4 before so learning on the job, always tinkered with VWs since I was a kid mind.

 

[Bav]

Wish I had the skills to tackle a self-build, but mine is paid for, not built (and, given my DIY skills, thank the lord for that!)

 

[Snowdawg]

I hate cutting windows in… and my next least favourite job is insulating so you are almost through the worst of it in my book downhill all the way now…. nice job and I love the roof!

Have you checked the drainage holes for your window as they can accidentally get blocked up with sealant on a self build leading to weird seepage?

 

[jimthevan]

Thanks man

Yeah hopefully all the good stuff to come now.

I have checked the drainage holes and they are clear at the bottom of sealant and they do drain when I pour water on the window

 

[jimthevan]

Well after a bit of time out from the T6 ( had to get the old T4 MOT'd and sold) - will miss that bus, 12 years of travels and covered 130k in it, T6 has a lot to live up to!

Anyway back on the T6 project, picked up a Califonia bench / bed and rail system from the Lakes, lovely trip up there, so then had the joys of finding all the correct brackets/bolts
and a few missing bits from VW and then marking it all up and fitting the floor:

Load matt
12mm ply
finished off with Altro.

It was a bit of a mission but happy with the results.


Next big Job on the list is the Electrics so I have purchased :

Renology Core 100AH
Victron 30A
Victron MPTT

to go with 200W solar for the roof

and a load of wiring, wish me luck!

 

[Bav]

Well after a bit of time out from the T6 ( had to get the old T4 MOT'd and sold) - will miss that bus, 12 years of travels and covered 130k in it, T6 has a lot to live up to!

Anyway back on the T6 project, picked up a Califonia bench / bed and rail system from the Lakes, lovely trip up there, so then had the joys of finding all the correct brackets/bolts
and a few missing bits from VW and then marking it all up and fitting the floor:

Load matt
12mm ply
finished off with Altro.

It was a bit of a mission but happy with the results.
View attachment 233853View attachment 233854View attachment 233855

Next big Job on the list is the Electrics so I have purchased :

Renology Core 100AH
Victron 30A
Victron MPTT

to go with 200W solar for the roof

and a load of wiring, wish me luck!

Luck!

 

[T6ChrisO]

Great little project thread, look forward to seeing further updates!

 

[jimthevan]

Seat is now in and LEDs wired up.

Really pleased with the seat/bench - to a bit of faffing to get the ali trims in sitting nice - I think I was too precise with the Altro cutout - not giving enough clearance.

Just need to shave a bit off under the seat to clear the wheel arch properly and that's done

 

[drinfinity]

The alternative to shaving the seat is to adjust the wheelarch. I used a block of wood and a hammer to press a channel onto the top of the wheelarch.

 

[jimthevan]

The alternative to shaving the seat is to adjust the wheelarch. I used a block of wood and a hammer to press a channel onto the top of the wheelarch.

ah interesting - i'll have a look and see if I can do this as it only needs about 5mm, but I have 10mm sound deadening all over it so may not work

 

[jimthevan]

Ok been a while since updated this but have been busy getting things done as we have now booked the ferry for mid June.

Lithium Leisure battery / Victron split charge & Victron solar controller installed


Roof rails and 200w solar panel installed, had the Alpicool T50 running for 3 days with no driving and just topped up by the solar and battery didn't even drop below 13.2 Volts - very happy indeed :


Finished of carpet lining:





Got some new rubber - Falken 235/65/17 ATs and powder coated satin black Devonports : )

The old Renault 4 served well loaded with 8 wheels and tyres:





Now starting to design the interior side unit out of Aluminium extrusion and birch ply:

 

[TallPaul_S]

Nice! Your aluminium profile units, are you going to separate the long pieces? Just thinking about safety - if that section running from the back of the van to behind the front seats is a single section, in the event of being rear ended it'll just get shunted forward and would end up spearing the seat and whoever is in it!

So think about safety and how it would crumple if you got badly rear ended. Maybe remove the middle section upper horizontal bits.

 

[jimthevan]

Nice! Your aluminium profile units, are you going to separate the long pieces? Just thinking about safety - if that section running from the back of the van to behind the front seats is a single section, in the event of being rear ended it'll just get shunted forward and would end up spearing the seat and whoever is in it!

So think about safety and how it would crumple if you got badly rear ended. Maybe remove the middle section upper horizontal bits.

Yes the long pieces are separated into 3 but bolted together with connectors.
Hadn't thought about it in an accident so a very good point.
Also the work surface will be a long sheet of ply, although split with a hinged lid - thanks will put some more thought to it

 

[z1ts]

The old Renault 4 served well loaded with 8 wheels and tyres:

Love, love, love the R 4 !!!!! I need something cool like that!

 

[jimthevan]

Love, love, love the R 4 !!!!! I need something cool like that!

The most practical thing I own, dirt cheap and rad as ! Get one in your life . Much simpler than this T6 milarky

 

[jimthevan]

Well after being ill then putting my back out this only left me with 6 days to build the interior unit and plumb wire everything up before our Europe trip so was all a bit rushed and rather stressfull !

I think we came to the final hour before leaving and we just threw everything in and went.

It's far from finished but it served us very well indeed -

Split charge/Solar/battery and fridge performed great apart from having a voltage drop due to the mega long lead the Alpicool is supplied with so had to do a temporary fix to shorten the run.

We slept downstairs mostly as the bed was super comfy with a 10cm self inflating mat on top. The fridge generated a bit of noise sleeping next to it but nothing unbearable.

so happy man.

Now just to finish everything off now we are back:

Draws
Finish Back unit
Bed shelf
Proper table
Tidy up unit electrics
Headlining of bed boards and cover for pop top hatch
Attach 4x4 sunshade

Here are some pics of the build:

Scribing the unit around the wheel arch was rather challenging!




Cut out for the 9722 hob/sink unit






now just to finish it all off

 

[jimthevan]

Here are a few from our trip : )