the work begins

Started converting a VW LT 35 panel van into our new mobile home. 
Took ages to find the right van.Much research on the net to find materials etc. 
Being a Yorkshireman I searched out second hand where possible!

The combined sink/hob                                        cooker                                   and 3 way fridge
together cost less than a new fridge. Definetly worth worth searching the net. 
Found a caravan breakers near Pocklington where I got the above items, all in mint condition.
Hooked the all up to gas and electric supplies to test them before installation.

Started work in hot weather, so bought skylight and 
fitted it so I didn't die of heat exhaustion.








Installed wiring, mains and 12volt.


Insulation (rock wool) very cheap lately, was an uncomfortable job, 
but essential for an all climate van.
Timber framing (2x1) fitted first, drilled and self tapping screws with O'leareys adhesive.

Insulation stuffed into all cavities, then space blanket and wall boards bonded and stapled to timbers. 

Lining the roof was tricky, you need loads of timber to supportboards and insulation, till the adhesive sets. (Much neck and arm ache, next day!)

Fitted solar panel to charge leisure batteries, with allowed me to use power tools with the inverter. Saved me dragging extension leads from house and across pavement.








           The kitchen
 Much thought, careful design and measuring involved. Have 1mm clearance at back of van! Had to raise worktop 1" so fridge would sit on wheel-arch. Notice the ever useful battens holding splash-back in place 'till the adhesive set.
You can just see the framework for "cloakroom" on the right.
Kitchen made from exterior ply and then laminated with furniture boards.




See the tube of O'leary's adhesive on the floor, learned to assemble everything 'dry' before using the adhesive (mistakes don't come apart easily!)

 Pretty much finished kitchen, overhead lockers (handy for hiding cables), and double glazed window with reflective blinds.
Note the 'bungee' strap, still sourcing decent door catches, as magnetic ones are crap!

                             The Bed Settee.

 Bed settee made from 2"x2".
The base slides out to form the bed.
Searched all over for cushions (silly money) found this excellent Futon mattress from Futon World on the net. Very reasonable and very comfortable.


You can see the swivel passenger seat and over-cab storage.
Curtains are temporary ones, as I didn't want to damage new ones.

 Storage drawers are ply, laminated on fronts, and mounted on kitchen drawer runners.


The seat is removable when not needed. Behind it is the utility locker with water tank, gas and storage.

Second Window fitted, again with blind and fly-screen.
Curtains hung on standard domestic curtain-rail.

The Table

Single post table fitting is easy to fit. Table and post easy to remove and store away. Table top was from an old dining table, cut out with jig saw, sanded and varnished. It can be rotated through 360degrees depending on where you're sitting. Had to be careful drilling floor, as it's above the fuel tank!

Wardrobe and Cloakroom

Units built on 2"x1"  frame and finished with furniture boards. Doors are ply laminated with same boards on both sides (to prevent warping).

Removable shelf in wardrobe hides leisure batteries, charger and 1800 w inverter. Inverter has been a godsend as it happily runs jig-saw, sander etc.

Electric control unit controls mains and 12v power. Meter shows state of leisure and vehicle battery. Cigarette  lighter adapter is hard wired into unit for various appliances.

 Drive-away awning from Riversway Leisure (£129) can be fitted to van by awning rail or straps. Zip up back door and drive away.

Last job is to fit standard V W window in sliding door and fit trims.

Lessons learned:-

• You can't plan enough
• You can't check measurements too many times
• Do your research, it can save you a fortune.
• Do your research, many others have built vans and their advice is useful and saves time.
• If you get pissed off, walk away for an hour, a day, it always seems easier after a break!
• If your not sure what to do, get expert advice.
• When using adhesives, make sure you have worked how to hold things in place, before you start.
• If you're not sure about gas and electrics DON'T do them! Get help. Test them.

List of suppliers etc.

F. Cross Volkswagen. http://www.fcross.co.uk/ Scunthorpe. Supplied the LT35 van. Excellent service. 

Very Helpful staff.

http://www.adrianflux.co.uk/  If you have any insurance problems, these people are spot on.

     (My previous insurers, Lloyds and Camping and Caravaning club weren't interested!)

 http://www.olearymotorhomes.co.uk./ Woodmansey, Nr Hull. Almost anything you might need. I bought boards, adhesives, pipes, trims etc Great place for advice!!!

Riversway Leisure http://www.riverswayleisure.co.uk/ Portaloo, awning, lots of special offers.

The Woodman, Sculcoates lane in Hull. Worktops, timber, trims.

B&Q For plywood. Measure up before you go and they cut for free.

http://www.feoffeecaravans.co.uk/  Near Pocklington, East Yorks. Pre-used cookers, fridges and loads of accessories
http://www.futonworld.co.uk The Futon for the bed/settee is very comfortable and does the job perfectly!