TallPaul's Caravelle - MTB wagon!

[TallPaul_S]

Progress on the same bit above, it's now almost done.


The 2 ducts in place, with one going to the front of the unit, in between the fridge and the back of the drivers seat, leading to a vent on the front.



I'll have storage to the right of the vent, big enough for cans of food. Then another shelf above the ducting, as it'll be capped off on top.

This bit of the unit is by far the most complex, once this is done I should be able to race through the rest!

The cut out on the left side is for the seatbase plugs, I'll be running a connector through this to a fusebox in the unit for the fridge, lights, water pump and some usb ports.

I've got a day off work tomorrow so will continue with this, should be able to get this section fully completed.

 

[TallPaul_S]

More progress, still a way off though - a couple more bits to cut and then a load of finishing bits (socket and switch cut outs, water container tie downs, holes for the ducting route...)

Oh and I need to drill the mounting holes for the fridge in the unit and in the fridge!

A slight alteration to the design, it's not going to have rear panels or doors - the slot in the right side front will be to hold a Campingaz CV470+ cannister and regulator (it'll be turned off and disconnected when not in use) - to get this in alongside the water containers I've chosen, they need to poke out of the rear by about 10mm, and due to how close the unit is to the sliding door at the top, the panels would need to sit inside the vertical sections. So there's just not enough space for any rear panels.

It does mean a bit less work for me though!! And it'll mean easier access to fresh/grey water via the side door, and more cooling for the fridge.






The far right cut out is for the 2nd of the 2 vents for the air heater. I did a quick and dirty test of the vents without the intakes being secured in and there was no air coming out around the vent section, it was working brilliantly.

 

[TallPaul_S]

Oh and the clearance to the weird jutting out section on the C pillar, yeah that was completely by design that it just clears it and that there's enough room for the worktop overhang...

 

[TallPaul_S]

Not the best pic but I'm now, after completely disassembling the pod to make some necessary cuts and adjustments, reassembling for the final time. Just need to drill the fridge and the unit to mount it and make a couple of other small bits to raise the water containers off the rail thumbscrews and spacers for the underside so it's all level.



I've got the sink and tap coming this week, so I'll get to starting work on the worktop this weekend hopefully.

These are my 2 bits of solid walnut worktop. The big bit for the main worktop and the smaller bit for the pull out table which will sit above the sink.

 

[TallPaul_S]

The kitchen pod is now 99% dry assembled, just a couple things to do when I next take it out, like a spacer for the bottom near the vent, and a couple of holes for the wiring. The duct underneath has p-clips but they have to be mounted before I put the unit in, and it's a 2 person job to put it in.





The fridge is also drilled and mounted in the unit, I'll be ordering some cap head screws and sleeve nuts to secure it rather than the self tapping screws it's held in with at the moment.



I'm waiting for a blanking plate for the single CBE socket which will go in the round hole on the left side, this will house my 4 switches for the fridge, USB sockets, water pump and dimmer switch for the LED lights. Once I've got all the electrics I'll mock that up.


I also need to order a guide bush and router bit so I can get to work on cutting the worktop.

 

[TallPaul_S]

Big update time. The kitchen pod is done!!








It houses:

50l fridge
Big sink
16l fresh/grey water containers
Space for a Campingaz CV470 plus cannister
2x USB and 2x std USB charging ports,
1x 3 pin powered from hookup
Storage for tins of food plus other bits
Dimmable LED down lighting
Flexible over worktop light
2 burner Cadac 2 Cook 3 Pro Deluxe QR stored under the pull out table
And a pull out table

All the electrics are switched and fed via a 50a Anderson connector into a fuse box on the unit. I've got an additional Anderson connector feed for some lights and USB ports for the rear of the van which I'll add later.

The led strip and flexible light isn't enough really so I'll plant to add some led strips above the doors soon, powered from the leisure battery.

I'll get some pics with both bikes in tomorrow, to prove it all fits (just!).


Next job, the bed!!

 

[PeteJS]

I look forward to reading your posts. That is a real nice job.

 

[TallPaul_S]

Pics with 2x full size (and by that I mean LONG) mountain bikes, 29ers.




Did I mention space was tight?




But, it all fits!! The bike on the right (looking front the back) is the longest bike I'll ever have so if this fits, anything will!

One amendment to the kitchen pod, the drawer doesn't hold open (the drawer runners have the hold in function but it's not strong enough) so I've ordered some neodymium magnets and ferrous metal tape, I'll attach these to the rear of the drawer which will hold it closed.

 

[TallPaul_S]

Bed design.

This took a load of head scratching and trying to find the right tools for the job. I wanted something that slid out partially, and after hours of YouTube videos, I came across these guys:

At 14 minutes in you can see a pull down and slide out bed.

After much much more searching through their videos to see how they were doing this, I screenshot this:


Which was EXACTLY the type of sliding mechanism I was after. After a load more googling, I found the slider.

DA0115RC/RCH Linear Motion Slide

The DA0115RC/RCH Linear Motion Slide supports up to 130Kg in weight when mounted vertically. This drawer runner is finished in Aluminium (DA)

motioncontrol.metrol.com

I've ordered these, and the rest of the bed frame will be made of 30mm aluminium profile.

This is the design. In bed function, the panel on the left is one of the 2 uprights already in my van.



The right legs will be on u joints which lock into place. The left legs will be removable with thumb screws. Same as in the video.

The right section will fold upwards, and the middle section will slide into the left section, also as per the video. In folded form:



So, in normal every day use, I'll have 4 seats (Inc driver), which easily fits 4x of me at 6ft 3in.

Then when camping, I'll either fold the rear seat and slide it as far back to give the middle seat more room, or remove one seat which will give me a load more room.

Then in bed form, I'll fold both seats, pull out the bed, attach the 2x legs, then fold down the last section and fold out the legs. Arrange my cushions and I'm done! It's only a single bet but I've slept in far worse places and it's likely to be much better than a tent!


Cost-wise, it's not a cheap option, the slides are £100 with the tracks, and there's £200 worth of aluminium profile and fixings in there too! Then there's the foam for the cushions which is about £120...

Oh and I've also got a set of window bags on order from 50° Nord:

I need these to make sure the bed frame clears them. They'll also act as blackouts for the rear windows, and of course some much needed storage!

 

[TallPaul_S]

I'll probably need to set aside some budget for a visit to @CRS Performance to sort the suspension - it's on std caravelle suspension but has had 30mm (sport line) spring fitted, which means it's sitting pretty low! It scrapes the front mudguards on my work speedbumps which aren't particularly big. And I've not yet got all the stuff in the back of the van yet.




I want to change to BFG K02'S on a set of OZ rally raids, and as it is id only fit 225/65's - but I reckon with a set of std springs, koni special active shocks and a 20mm lift kit that should take me back to just over std (non caravelle) height which will allow 245/65 BFG K02'S.

 

[GruB]

Fantastic use of space for your bikes. The dimpled black flooring is to make any mess easier to clean up I guess. Do you cover them if they are muddy?

 

[TallPaul_S]

Fantastic use of space for your bikes. The dimpled black flooring is to make any mess easier to clean up I guess. Do you cover them if they are muddy?

Yeah it's just rubber coin matting, makes brushing out the bike drawer easier.

I'm planning on adding some extra water storage for washing the bikes if they're really dirty before they go in the van. I've got a worx hydroshot pressure washer so just need some extra water (I could use the sink water but it gets through water fairy fast).

Covering up the bikes is also an option I'd not looked into, might see what covers I can make!

 

[GruB]

When I was cycling the best Father’s Day present I received was a Minoura bike workstand. With that and minimal tools I could fix most things. There may be lighter more portable ones nowadays.

 

[roadtripper]

Seeing that all come together that's an impressively elegant solution, brilliant. I love the fact it works for what you want but you've still got 4 seats and your pod looks like a nice standalone design for camping even if the bikes are not there.

Can't wait to see what you do next...

 

[TallPaul_S]

Seeing that all come together that's an impressively elegant solution, brilliant. I love the fact it works for what you want but you've still got 4 seats and your pod looks like a nice standalone design for camping even if the bikes are not there.

Can't wait to see what you do next...

Cheers! Yeah it should work for me, obviously I haven't used it in anger yet but it should be fine.

Once I've got the bed done, and got the remaining curtains installed I'll take it for a test night.

The only thing that's going to be tricky is storage space, and drying/storing wet/smelly clothes. But that's like any T6, and worse if I was camping.

I'll have a couple of drawers at the back under the bed, then the 2 window bags, and I need to do something with the space between the bikes and the drivers side, there's space for a full face helmet and stuff. I'll get a seat organiser, and basically try and make use of every nook and cranny for storage.

I'll remove one if the rear seats on anything longer than a day or 2, that'll give me both more space to move about in the van, and more storage space for stuff.

 

[roadtripper]

I'd be tempted to think soft storage, a selection of heavier duty dry bags as used for sailing etc are great for storing clothes and gear and keeping mud in (or out) and can stuff into all the odd shapes and maybe even between bike bits.

 

[TallPaul_S]

I'd be tempted to think soft storage, a selection of heavier duty dry bags as used for sailing etc are great for storing clothes and gear and keeping mud in (or out) and can stuff into all the odd shapes and maybe even between bike bits.

Ah yes, I do already use a set of karrimor dry bags - crucial for storing stinky, sweaty kit when camping!

It's also the masses of paraphernalia that goes with mountain biking - helmet, shoes, gloves, knee pads, backpack etc etc.

A week long trip will be the real test.

I will add I'm no stranger to having to pack light and fit stuff in a limited space - this was my motorbike for 2 weeks in the Alps, mostly camping


And a week long camping trip in Germany


So I don't think fitted a week's worth of clothes and kit into a T6 should be a problem!

 

[FerrisBFW]

I'll probably need to set aside some budget for a visit to @CRS Performance to sort the suspension - it's on std caravelle suspension but has had 30mm (sport line) spring fitted, which means it's sitting pretty low! It scrapes the front mudguards on my work speedbumps which aren't particularly big. And I've not yet got all the stuff in the back of the van yet.

View attachment 237735
View attachment 237736

I want to change to BFG K02'S on a set of OZ rally raids, and as it is id only fit 225/65's - but I reckon with a set of std springs, koni special active shocks and a 20mm lift kit that should take me back to just over std (non caravelle) height which will allow 245/65 BFG K02'S.

Amazing build well done. Re: wheels, tyres, springs etc on a Caravelle

I rebuilt the front end last spring on my Caravelle 5.1, I went for std steel 17" wheels with Falken Wildthingy 235/65's for a trip tho the Alps this winter, and must admit they have transformed the ride and I want to keep them the whole year now. Rear is a little soggy so I have bought Koni rear shocks and rubbers from CRS, and as an experiment I am going to try some t32 delivery mileage springs.

So -20mm Caravelle springs are grey/grey/orange on the front and green/green/orange on the back currently, and have grey/grey/grey/green - front, and grey/grey/grey - rear. I will try the rears on their own and see how they are, I am hoping for +20mm and stiffer rear. What I can gather is there are three rear spring options for std height t32 1x, 2x and 3x grey. They were cheap enough to get another rear set of the lower weight if 3x grey is too much. I will post pictures before and after

 

[TallPaul_S]

Window bags received and fitted


Excuse the mess, I'm also part way through installing extra interior lights running off the leisure battery, and pre wiring for a solar panel.

PV cables run via the tailgate wiring boot into the space between headliner and roof. They're sealed with caps so I'll be ready to install solar in the future.



Extra rear light installed to give illumination out the back when I'm on night rides and loading up a bike in the pitch black




And extra interior led strips which will be mounted above the doors



Now the window bags are installed I've been able to check exactly how much clearance I've got for the bed frame. So I've done a bit of fine tuning of the design.


That's it in folded and unfolded states. There's enough room for the 2 rear seats for me to sit comfortably at 6ft 3in.

The bed will be 1.8m long, so just under 6ft. 55cm wide, just under 2ft - but the extra bits on the right which overhang the frame are to fill the gap between the frame and the van interior. That makes it 70cm wide. If I can work out how to have some extra frame or something there, I will, but it's more to let me spread out and not lose stuff down that gap!

I'll have some USB ports, a light switch, and a flexible reading light mounted on the inside of the 'headboard' and a couple of switches for the boot lights mounted on the other side.

There's £220 worth of aluminium profile, fittings etc in the bed. Plus the foam, plus the fabric. So probably £350 or so total.

 

[TallPaul_S]

Wiring all complete on the interior light strips, rear floodlight, and PV cables all completely hidden, routed through the van internal trim and headlining.

I'm really pleased with how the lighting has turned out, and I'll probably add a little more 'uplighting' via LED strips in the rear of the van, shining up but hidden to give more soft light options.



There's basically zero light leak from the curtains or the window bags, you need to be 1ft away to see any light from the folds of the curtains. Anything more than that and it's just a dark van with no lights inside.


Made my own dimmer switch mount that fits into the grab handle mounts (I'll finish it and paint it later on).



And I've just ordered the bits required for the bed.

10 metres of aluminium 3030 profile, 150 tnuts, etc etc!

I've got all my cuts and sections worked out (thanks to tinkercad!), I hopefully should be able to get this done in a couple of days once it's all delivered.

Then it's just the foam to order for the bed, and the use of my mum and her sewing machine to make the covers.

Tailgate and cab divider curtain after that, and it'll be ready for it's maiden voyage! Ie. First night camping in the van!!