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Discussion Starter #1 (Edited)
Hi guys and girls i thought i would bring my next new project here, as there is a lot of knowlage here, so it would be great to share my build with you,
I have many ideas in my head but most wont happen but here goes on my plans

I do the odd track day and having done a few now and seen many cars not drive home, i think I am pushing my luck with the drive to and home approach.
hence the van to tow the car to track and be able to spend a few nights away in it,
i also want to be able to pack the wife and be able to disappear around our fair land to see a little bit more, when not being used to tow

so with in the last week i have picked up a SWB 2007 Vivaro on 81kmiles 2 owner van

20170130_114936 by paul vincent, on Flickr

the van was a wales utilitys van untill 2013 so is fully kitted out with rear racking roof rails and even flashing beacons

20170130_115016 by paul vincent, on Flickr

what will need doing.....
everything really from
stripping out the bulkhead,
insulating,
cladding,
flooring,
storage,
utility's,
tow bar,

as you can see its not going to be a five minute project
more of an ongoing Evolution of a Van in use

so my first job is to strip all the rear to bare shell and remove the bulkhead
basicly this is the start of my project and the photos will start once the rear has been cleared

enjoy
Paul


Cullys SWB Vivaro conversion
Index of Tasks

The start,Loom move,sound proofing,Towbar
240v Input,side windows,insulation,boarding
First fix electrics, roof boarding, floor insulation
Carpeting,Floorcovering,Rooffan,Van Bonding points,secon fix bling
Kitchen Plan+instal,roof light wiring+diagram
Kitchen Fitting,Battery Fixing,12v fuseboard,12v heavey current isolators
240v fuseboard, heavey current drawing,Inverter+charger location
12v control board,cupboard doors
Gas/water storage
curtains
Bed
Hidden fuel filter, top mounts,VSR,rear doors covering
Tracker, side door covering
Parts list,rear doors covering
Slide door step
DVLA Pictures,Drive away awning
DVLA letter,
electrical drawings
Brakes refresh
heating
Solar charging
Wheels
 

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Good luck with your conversion that looks like a well racked out van I guess you'll be able to sell the racking
on eBay?
Look forward to the photos.
 

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Premium Member
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343 Posts
Discussion Starter #3
Good luck with your conversion that looks like a well racked out van I guess you'll be able to sell the racking
on eBay?
Look forward to the photos.
Thanks and yes i hope to get some cash back to put back into the van ;)

while ive been stripping the van I have found its fitted with a second battery, split charge circuit aditional 12v lighting and a 12v hot water dispenser for hand washing
all this and the beacons are powered via a seperately installed loom and 12v fusebox which some or it i can use with modifications
 

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343 Posts
Discussion Starter #5 (Edited)
been busy today managed to remove the bulkhead, all the internal side panels,
and all the secondary loom, but I'm struggling with the roof rails some kind person nut and bolted them through the roof onto load spreader plates inside,
I'm having to adapt the spreader plates inside with some Rivnuts to enable me to use the rails again if needed,
as i wont be able to get to the nuts when a new roof is fitted inside.
also making good and water proofing all the existing drilled holes in the roof

:)

spreader plates with added rivnuts

20170202_195120 by paul vincent, on Flickr

sealing the roof holes with the use of stainless bolts Tap washers and silicon sealant

20170202_195101 by paul vincent, on Flickr

looking a lot larger inside now!

20170202_195204 by paul vincent, on Flickr
 

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343 Posts
Discussion Starter #8 (Edited)
todays mission!
1: remove the roof loom from front to back with the hope it will make things easier later
2: splice in the tow bar electrics while moving the loom

20170205_161652 by paul vincent, on Flickr

marked all the cables all 29 then cut them!

20170205_161640 by paul vincent, on Flickr

once the loom was cut i worked out the 6 cables needed for the towbar socket, then fed the cut loom back through the channelling of the roof
then soldered and slieved all the joints, tape wrapped it and sat back and admired the new clean lines!

20170205_182745 by paul vincent, on Flickr

20170205_182753 by paul vincent, on Flickr


for info....

trailer wiring by paul vincent, on Flickr
 

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343 Posts
Discussion Starter #9 (Edited)
some progress on the van in the last few days,
I've fitted a brand new witter Towbar, the kit fitted nice and easy all electrics in and working No isolation relays needed ;)

20170212_184002 by paul vincent, on Flickr


ive started to cover the larger internal panels with Flashband this is to cut down on the road noise inside the van,
I was surprised how effective it is, it certainly reduces the drumming noise

20170212_184050 by paul vincent, on Flickr

20170212_184054 by paul vincent, on Flickr

20170212_184109 by paul vincent, on Flickr
 

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Discussion Starter #11 (Edited)
NEW tool day!
bought a clark nibbler for cutting out the windows, this one fits to the drill chuck
practice run by cutting a hole for the 16amp inlet
nice and easy to use and control, with a good finish

20170215_144034 by paul vincent, on Flickr

painted all the new edges and silicon sealed the box back against the van

20170215_145836 by paul vincent, on Flickr
 

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Discussion Starter #12 (Edited)
sun is out so Ive taken my man up pills and fitted one window! :D

check window is the right one befor i cut a hole!

20170216_092845 by paul vincent, on Flickr

remove inner door ribs by drilling the spot welds

20170216_092911 by paul vincent, on Flickr

drill access holes for nibbler

20170216_094245 by paul vincent, on Flickr

Get brave

20170216_095030 by paul vincent, on Flickr

20170216_095621 by paul vincent, on Flickr

offer window up

20170216_095915 by paul vincent, on Flickr

remove panel bonding glue so inner trim can be fitted

20170216_103809 by paul vincent, on Flickr

follow instructions on glue/PU bonding supplyed

20170216_111436 by paul vincent, on Flickr

20170216_111442 by paul vincent, on Flickr

throw window at hole and hope for the best!

20170216_112354 by paul vincent, on Flickr

stand back and admire handy work!
 

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Discussion Starter #15 (Edited)
started on the insulation
larger box profiles have been stuffed with insulation
side will be foil bubble>recycled plastic insulation>foil bubble

20170217_132339 by paul vincent, on Flickr

20170217_134541 by paul vincent, on Flickr

roof will be the same foil bubble>recycled plastic insulation>foil bubble

20170217_163645 by paul vincent, on Flickr

20170217_163704 by paul vincent, on Flickr

for the O/side i need to get some some timber to add some fixing points for securing the furniture
also need to get some battens for the ceiling fixings
 

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Discussion Starter #19 (Edited)
been a long day today cutting wood offering up cutting and trimming

have fixed one panel, have also put in a timber to fix the kitchen too, and also finished fixing the battens to the cieling, have had to move some cables around to make fitting panels on the other side easier, have also routed the 16mm battery cables and created Earth bonding points for the 240v and 12v- wires

I will be glad to go back to work on Thursday for a rest :)

20170220_102642 by paul vincent, on Flickr
 
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