So, design number 201; time to crack on... OK it wasn't quite that number of designs but there had been a few and it was time to get started with the first fix and to stop procrastinating. As it happened things changed again and I didn't end up with this version either... but creating layout ideas is instrumental to deciding what power you need and where you want to install it. After the floor was completed, I wanted to get the electrics sorted before I insulated and fixed the walls and ceiling, to save having to do lots of fiddly cutting later.
Initially I wanted to do everything on the build myself but I had to face facts and realise it was a pipe dream; I just didn't have the tools or experience to do some of it. So I called in the pros and sent Buttercup to Mark1 Conversions where they followed my many sketches and electrics plan, to install the solar panels, leisure batteries, fuse boxes, 240v hook up, side window, skylight and ceiling fan. Yes, I probably could have figured out the majority of it and could have fitted the windows and fan myself, but it's super scary taking a jigsaw to your lovely van and cutting a huge hole in it! And what if I ended up blowing myself up by using the wrong batteries or fuse or something... my mum would have killed me!!
The guys did an amazing job and soon Buttercup was home and I could crack on with the wiring, insulation, getting some new walls and ceiling up and installing the lighting. I was getting to the exciting part now of being able to add furniture and decorate... but first the tricky job of installing giant ply sheets on your own.
Insulating seems to scare people, but honestly, it's the simplest job to do in your conversion. Grab your wool, stick it in the many holes around your van and ensure no metal remains exposed (bar the ribs, as you'll need those next)... It's that easy!
The ceiling is a little tougher but we'll discuss that in a mo. Oh and get your wiring in place, as per your plan, for your sockets, fridge, water pumps and lights before you start.
Your van is now all toasty warm and you need some walls... OK so at this point I had a complete melt down and thought I couldn't go on. I was fighting with huge sheets of 9mm ply and just couldn't manoeuvre it around on my own, let alone hold it up to measure, cut and secure it. So, Dad to the rescue...
We battled on with lots of cursing, sawing and re-sawing, and a spot more re-sawing, to get the panels up. Van's aren't level by the way... no point even trying, just feel your way! Again, it took two days and not the 8 hours I had scheduled in my project plan, to get the walls up. They aren't perfect, not particularly the smooth clean look I had first envisaged, and we had a nightmare getting the right screws to grip the metal ribs, but it was done and I felt happier. Dad deserved a well earned holiday and I decided to crack on with the electrics and painting the ply. FYI, I don't normally paint with my pinky sticking out; I had broken it a few days before hand on my mountain bike!
Next up I wanted to get my bed frame made... From the start this involved lots of measuring, mocking up the space, ensuring the bike would fit and sitting staring at the wall! But tah dah, I did it. It's quite possibly the chunkiest frame known to man but it works and I was so proud to have built it all on my own, and it's super sturdy and comfy.
Final job for this session was to install the ceiling... I decided to go with tongue and groove to bring a different texture to the space. I bought 3m long T&G as that was the longest I could sourse, and decided to go with just one join, which I could then cover up. I'm not going to lie; it was the hardest thing my Dad and I have ever done, and we've done a lot of stuff! After another round of sitting staring at the walls (you do a lot of that when converting a van!), I figured out a way to keep the Celotex up whilst the Silkaflex dried (long bits of wood and some random stuff lying around!) and then I created a really simple system to attach the wood to the van's metal roof ribs. I glued and screwed a piece of 9mm ply to each rib, so we could then pin the T&G to the ribs without having to try and avoid the MANY holes there are in these joists. That worked really well, the next challenge was just to get the wood up... we used panel pins and brute arm strength. If you've got a pin gun, use it, or borrow one, or steal one, or hire one... it will save you a lot of pain! Again, it took days and not hours as expected but the results were totally worth the hard work.
So, finally after a lot of blood, sweat and tears... plus a lot of coffee and singing to uplifting tunes to get us through... we completed the first fix.
Time for a lie down in my new home...
So impressed with your tool skills 😮