Puff the magic wagon

[Toffermora]

So today has gone better than the other day! I have a window on the van and it didn't destroy itself! Wether it leaks we will see tomorrow!

Also finished grinding out the bulkhead and got that painted and also took out the rubber mat to give it a good clean! It has come up quite well. The floor underneath had about a 1cm tall mound of dirt from where the RAC drivers must have rested their foot!


Also sprayed my badges black. Not the greatest finish but they will do for now until I decide what I want to do.


Also got it booked in for it's pop top and smart bed and ordered some panels and a carpet!

 

[DaveCrampton]

Paint those badges' background Orange!!

 

[TeeCeeJay]

Its looking good. I ground and drilled our bulkhead out a couple of weeks ago. Good luck with your build, will be following.

 

[Toffermora]

So the window doesn't leak!! So at least we don't have that to redo. Managed to remove the last of the wiring! Had two wires running through the bulk head, I presumed one was the battery cable but didn't know what the other one was. Ended up removing the battery, arch liner, and half the bumper trying to trace the last one! Ended up an hour later finding it had been cut at the other end anyway!

Left the battery wire and rerouted to under the driver's seat ready for whatever electrics I do.

Then got the rubber flooring back in and seats back down ready to drive to work tomorrow. Ended up finishing it as dark was falling so couldn't get pictures of the nice clean floor!
Need to put some rubber grommets in the last couple of holes in the floor then spare wheel liner and spare wheel back in when I get chance then onto sound deadening and lining!

 

[Toffermora]

So not achieved much lately due to it being Easter holidays and the weather has been a bit poo. But did get my Climair wind deflectors fitted after asking on here about the screws.

Then today been sound deadening and insulating:


Had to do it with a helper:

 

[Toffermora]

New headlights arrived yesterday and with the kids back at school I had most of the day to myself.


Really pleased with them, just need to get the dip and main coding done.
While I had the bumper off I removed the chrome strips to spray them and resprayed the badge with the textured truck bed liner spray.
Also managed to get one wheel arch sound deadened from the outside. Get the next one done tomorrow hopefully.

 

[Toffermora]

I started carpeting today! Overall went ok, few bits are not as good as I wanted but I started with the side that will be hidden by the kitchen so hopefully when I do the other side tomorrow it will be better! I have left a section hanging down for when the pop top gets fitted. Hopefully there is enough and I don't have to get some more and try and join it.

We have got some panels to go back on when I have fitted some bottle insulation and ran some wires.

 

[Toffermora]

So not updated this for nearly two weeks so thought I would, although not done loads. Went to Chris @Dav-Tec on Friday and he fitted a new headunit and reversing camera for me.

Unfortunately in doing so he uncovered some rust around where the previous reversing camera had been so some more work for the body shop! Hopefully I am going to speak to one next week and see what they say/ quote, the previous local one hasn't got back to me.
I ordered and received a load of electrics, now need to work out how that all goes together after the pop top and seats get fitted in two weeks!



I fitted a battery monitor for the starter battery today:


Finally I added a little bit of comfort in the front, although it's filthy already:

 

[Toffermora]

Van has gone this week to have its roof and seat/ bed fitted this week or so I thought anyway. The seat hasn't arrived so will have to take it back nearer the end of the month, which is annoying, was hoping to try it out over the kids holidays in a couple of weeks! Got sent some photos today of the roof so at least that's something done:

 

[Toffermora]

So van is back, spent the day putting the carpet around the poptop and the bed floor, we are thinking of putting a map or similar on the underside so need to find a design of that we like. I lost my front badge the other week so the replacement turned up today, ordered an orange back plate as well.

Not sure I like it though think I prefer the all black look so it may get sprayed tomorrow with my can of truck bed liner, which I used to spray the chrome grill trims. Ordered a sunglasses holder which also turned up today so I am thinking of taking the headliner out tomorrow sound deadening and insulating the roof above that before I put it back with the sunglasses holder.

Made a cardboard box the same size as the battery I have ordered, it's not due until the end of June so I made a box so I can look how I can fit it all under the seat.

 

[Toffermora]

So took the headlining out today so I could finish off the carpet at the front of the poptop and then also sound deaden and insulate what's left of the roof.

Apparently I didn't take any photos of the after! Tried fitting the sunglasses holder but realised after I made the holes and wondering why it wouldn't fit, then reading forum posts that I need the bracket attachment thingy like the other side! So left that for another day, annoying I now have holes in the headlining!

Didn't like the orange front badge so I have sprayed that and the badge.


Started fitting my panels back in place as well, not sure about the tailgate ones though

Got an extra hole in the lower one, which I assume is for the switch to open from inside which I don't have. Then I am not sure how to fit the top one yet.

It comes with these plastic blocks:

But no instructions so unsure whether they go behind and then you screw the panel to it or they go Infront but then obviously you see them.

 

[DaveCrampton]

I have a tailgate on my shuttle. The upper hole is the switch to open from the inside. The lower is for the strap, which is used to pull the tailgate down.

 

[Toffermora]

So gave it a wash today and fitted the now black badge


Then thought i would start wiring up the lights.


It's starting to come together, can't wait for the seats to go in, then at least we can start using it as a family rather than relying on the wife's tiny electric car that has terrible range.

 

[Harry_t6]

Good work! I will be keeping an eye on this feed

 

[DaveCrampton]

I have a set of small circular thin LED 12v lights in my van. They turn on and off when you touch the metal. I must have brushed against one for a longer time as one was very dim, and for a week I thought it was a faulty earth but when away kayaking a friend pointed out that if you hold the metal ring when lit thee dim, then hold it again and they illuminate to full brightness again!
Every day is a school day!

 

[interbear]

Awesome thread. Much respect, I couldn’t even begin to do this type of work, bought my van from a converter, all done. Great to see how it advances step by step, it’s quite fascinating for someone who wouldn’t know where to start with this type of work. Well done @Toffermora

 

[Toffermora]

Thanks @interbear, I haven't done anything like this before but I think what I have done so far everyone can achieve, all I did was follow what others have done on here and YouTube.

 

[Toffermora]

Bought some more insulation from b&q this morning to finish off the tailgate and passenger side. Also received some t tap connectors and button in the post for a tailgate switch.




Thought I had ordered a larger one but hopefully this way it's less likely to be pushed accidentally. Anyways it works so pleased with that.
Having my kitchen designed/ built by somebody I know and had a pic of the design sent to me today, it's coming together!
Also found out my seat/ bed has arrived at the fitters at last. But the rails were damaged by the couriers so now got to wait for more of those to arrive so it's going to be at least another couple of weeks until it's fitted!!!! So annoying!!

Just want to be able to use it as the family vehicle it's supposed to be!

 

[Toffermora]

So finally the seats are in!! Pictures sent from the fitters:



With the kids off school tomorrow due to strikes, we are going for a nice trip on the train to collect it!
Then we are going away for a night on Thursday to try it out so far.
Next jobs are swivel base fitting, solar panel hopefully at the weekend/ beginning of next week, then maybe some more electrics if I can work out where it is going to live, as it won't fit under the driver's seat.

 

[Toffermora]

So first family trip out today in the van, just an overnighter near York. Managed to get the swivel base in earlier.


Spent most of the time trying to sort the wires out underneath!