Rob's T6 Overland Camper Build Thread

Just got back from the UK with the van, pop top fitted, rock & roll seat fitted, kitchen fitted and carpet lined... here's a little tease smiley.gif

This week the BF Goodrich get fitted. Still need to install the full Victron electric system and the Webasto heater under the seat. Lots of photos coming soon.


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Whilst I am waiting for some better weather to come along, I figured I would plan the electric system. Yesterday fitted all the Victron bits into their spot. Now to start running the wiring from the front to the battery, then to the Lynx.

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Removed the front bumper as its time to fit the new one that has been painted. While the bumper was off, I measured and fabricated up some brackets for the spotlights. The bracket will be mounted to the chassis cross bar and up through the grille.

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These are the brackets, tomorrow they will get a few more snips to ensure a perfect fit, primer, a coat of black paint and on they go. The bumper will follow.

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Those lamp brackets look real heavy duty
Yeah they're made out of 6mm thick steel. They will be holding 7" spotlights further up, next to the VW logo so don't want vibration - making provision for the forces all the more when we are taking the roads less travelled. Learned from my mistakes when I made a custom bracket I made on my Disco 4 back in the day.

Will still trim down the gussets to fit through the grille
 
I just couldn't help myself, had to finish the spotlight brackets and install the new bumper! Curiousity.......!!

First thing was to test fit the brackets and trim those gussets for a perfect fit. Also marked up the holes at the bottom.

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The below photo shows how much they stick out and the gap from the intercooler.

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Test fit with the grill on, and to trial the spotlights and trim.

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Triming and hole drilling complete. Now they sunbathe a bit to dry the black paint.

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Bolted down... It was a tricky exercise getting those bolts in...

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Spotlights fitted. They have a neat profile and don't stick out too much I think!

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Also fitted the new bumper! It came out really nice!!!!!!!! cool.png

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I prefer these spotlights to the Lazer lamps! it works better with the Swamper offroad look I think!

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So happy with the result!!!
 
Yesterday the wheel fitment guys came around to install the new wheels and some new rubber!

OZ RALLY RAID 8.50x18 5x120.0 ET 38
BF Goodrich 255/55R18 KO2s

At the moment on standard suspension, no rubbing on full lock, no issues. Next is the 45mm lift.

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The van is no more wireless!!! wink.png Finished up hard wiring of the Victron system last night; that Lynx distributor is a game changer and will now be included in all my future setups!

Next is to set up the Ekrano screen and complete the Victron network with V.E Direct cables.

Last step of all the electrics is to install the solar panels on the roof, and then run the cables in to the MPPT. 3 x 175W panels on the roof + 100W switchable panel on the bonnet. By switchable, it has its own little MPPT which charges the starter battery when we are parked up for a long time, it can also be switched to add to the 525W on the roof making it a total of 625W of solar / roughly 38Amps charge per hour at peak.

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(Union Jack patch pays homage to the work done on the van in the UK)
 
It is all coming along nicely now. A couple of things, Their appears to be a fashion that has developed over the last few years towards short bridging ladders / sand ladders. I am not quite sure why that is but I would have thought shorties would be far less effective and might not be long enough to get a run going before having to stop to start over again. The other concerning the bridging ladders is recovery of the same. I should imagine that short ladders are more easily lost because they have a tendency to bury under the slime or sand what ever they are being used for. Years ago these things used to be manufactured from steel or aluminium pierced planking, so plastic is lighter but may flex more possibly so it might be e reason for reduced length but it may be because more people travel on expedition but then can not find anywhere to put longer versions. I do not know what the current advice is. In the past some have attached some sort of tell tail that floats above the immersed ladder short rope or even longer attachment to allow the ladder to follow the vehicle, so avoiding the necessity of a long walk back or a short one that might prompt getting stuck again.

The other thing that struck me was the lamp brackets, very useful and strong but also could cause tremendous personal injury. Not sure on solution exactly but rounding the corners might be one and linking them together with something a little blunter and person/animal friendly. Perhaps a length of angle iron/aluminium blunt side forward linking them might be the easiest and fastest solution. Could always add some padding wrapped in white reflective tape. Might make all the difference and reduce attention for scrutiny.

White is the best colour for vehicles I believe for hot days and climates and the mounting of a panel on the bonnet very sensible solution to reduce reflective glare. It reduces glare from strong sun and other vehicle lights or even ones own additional lighting if mounted high on the roof, less fatiguing on long days. It is not bulky or heavy and is an ideal solution, frees up some roof space too. BFG AT KO2 are very strong and robust will take knocks and stone abrasions in their stride far better than many other easily available tyres. Snorkel is good reducing the ingestion of dust and water. I would like and have use one of those, not sure about the dust here but water can be a great problem in wet Wales flooded fords and emersed roads. Keep us informed.
 
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