Photos and info on how to prepare the floor and install a ply lining for a camper build in a VW Transporter T4 van. Photos and info on how to prepare the floor and install a ply lining for a camper build in a VW Transporter T4 van. Home; Online Shop; Video Playlists. The first thing I did was remove the ply floor, and used it as a template. Free-hand cut as close as it gets. Then use a steady hand and a pencil and scribe a line while following the curves of the van. A drum sander.
xilusrabbit.cba.pl› Vw Transporter Ply Lining Templates For Resumes █
•New CV Joints •Replaced sliding door rollers and locators •Replaced rear lock mechanism. Exterior •Full re-spray in VW Golf R32 blue (Deep Blue Pearl) - Colour coded bumpers. •Full ply lined rear of van. The lining was purchased from a reputable supplier who custs the panels from VW templates. Nov 05, 2008 VW T4 Forum - VW T5 Forum. Ply lining templates. In fact I have all my ply removed at the moment lol but it's a swb.
Yes it is my second camper but the title of the thread was more in tune with Blur's 'Song 2' WooHoo and all that or possibly I need my head checking!! So for anyone who has not read my other posts on the forum this camper is to replace our beloved Type 2 Bay window which is currently for sale because we are looking after my mother who has dementia and we are basically housebound. The bay like to be used not just left sat there, also I have had to leave work to look after her so I need to consolidate my vehicles into one to save money as my sole income is a massive £62.70 a week carers allowance. So without further ado here is the old bay window that has served us so well Once the decision had been made I found a T6 in the VW dealers in Llandudno Junctiom went to see it and bought it, she is a September 2015 102PS Highline with a Euro 6 engine The first job was to rip the ply lining out, then remove the bulkhead (what a PITA that was) befor giving the inside a real good clean. I then ordered some 3.5mm ply for the panels and some 12mm ply for the floor. I used the existing panels as a template for the new ones using a bearing guided router cutter to follow the shape exactly. We had eventually decided to have lowline cabinets rather than a wardrobe similar to what we have and like in our Bay.
This obviously meant that we could have windows all round, my wife also wanted light green glass rather than the more usual 70-80% dark tint, these we eventually found and ordered. We also ordered a Streamline Easylift R&R bed (only 2 of us and we didn't need an M1 tested one), some blue 4 way stretch carpet lining, a Virtfrigio fridge and a Smev 9222 sink/hob, insulation and some Altro non slip flooring. Thank you Once everything arrived the first job was to sort out the sub floor, I used the old 9mm floor to make a one piece filler instead of using lots of individual bits.
The idea was hopefully the one piece construction (actually 2 pieces) would be more rigid and help reduce noise, secondly it could be placed on top of the actual floor to trace around with a pencil to make it easy to know where to screw down. I stuck the sub floor down with Sikaflex polyurethane adhesive, after it was set I applied the sticky back insulation in the low spaces. At this point I went for a drive and the noise reduction was remarkable, that should make long journeys more pleasant. The next stage was getting the windows in and the carpet lining done.
I wasn't looking forward to this bit so for the first effort I decided to have a crack at the barn doors first as they didn't need carpet lining. I masked the van up, drilled holes to mark the corner radii then cut the panels out with a jigsaw, filed the burrs clean and primed the raw edges with zinc paint and finally with primer and lacquer. The rubber edge trim was applied then it was off to re read the window bonding instructions. Once the primer and activator had been applied I started to apply the adhesive using a standard mastic gun. Big mistake, holy 'insert rude word here' it was heavy going, I bought an air powered one for the rest of the windows, bargain!!
In the end all was well and we had two windows in the back of the van. Now on to the side windows and the carpet lining. First I cut out the panels, primed etc and then moved on to the carpet lining. I was dreading this bit but in the end it turned out to be dead easy, a hair drier to warm the carpet up when it gets a bit tight and bingo. Once in I replaced the door seals and knocked on the rubber window edging over carpet and metal, an old RAC card made that job a lot easier.
Windows bonded on and the job was a good un, what was I worrying about? We carpeted the ply panels after fitting the invisible trim clips and fitted them, put in a layer of insulation over the sub floor, fitted and screwed down the floor and finally laid the Altro We also bought a Kombi step set to tidy the doorways up. Fitting the Streamline bed was simplicity itself, just a matter of dropping the spare wheel and drilling and bolting through the load spreaders, the whole job took about an hour and most of that was waiting for paint to dry Next I worked out the outer edge of the cabinets and laid a strip of masking tape to mark it. We put the fridge and water/gas in position to work out the position they would be in the van to allow access. Then using the cardboard packaging from the windows I made templates for the cupboard uprights.
Rather than use lightweight ply which comes with a foil finish we wanted to use a real wood veneer that I had in the workshop (these are hand cut veneers 3mm thick that were left over from a church suit of furniture I made many years ago); to act as a carrier for these we used birch ply which is only marginally heavier than the lightweight ply. Using the cardboard template we cut out the uprights and had a test fit The ply was then veneered sanded and sprayed and the cabinets put together, sorry no picture of this bit but it's hardly interesting stuff Just before fitting I put in the leisure battery etc under the drivers seat, what a PITA that was fitting it all in but it's done Now we could fit the cabinets I can't upload any more images so, next post.
Thank you for producing this thread dedicated to your conversion project as it deserves to be seen as an entity and show what can be done with time, patience, application and a willingness to give it a go. As 's conversion thread is a tribute to the work of, so this thread is a tribute to your expertise, tenacity and determination to do the best possible job even though you are using some techniques and skills for the first time.
You should certainly consider undertaking some conversion work for others from home as clearly you have a flare for this type of thing. A very worthwhile project and thank you for allowing us all the opportunity to share your efforts. I look forward to your next progress posts.
Finally took the leap and bought myself my first van! 2003 T4 with a pop top. For a year or so I toyed with the idea of buying a van/day van for the weekend trips to the beach. Company lease vehicle just wasn't cutting it for me, a mileage cap of a 1000miles per month is hard by anyone's standards not to mention transporting surf gear. On to the van: 53 plate (I'm guessing ex AA) 2.5tdi with 153k on the clock.
Interior (For the time being) Within the first 3 weeks of purchasing the van it was time to address a few things highlighted when viewing the van: a friend (Vw technician) and I set about replacing the brake disc and pads all round, the Timing belt & water pump incl. Fuel pump belt. Back on the road and all seemed well. So I thought. I started to hear a light rattle on idle that appeared to be coming from alternator side. On inspection the alternator belt appeared to be 'slapping' on idle, knowing the alternator had been uprated it raised some questions.
Under throttle (raised rpm) the rattle couldn't be heard, the noise developed highlighting the cause of the rattle being the dual mass flywheel. Knowing the gearbox needed to come out, we decided to remove the engine as well. An opportunity to investigate an oil leak that was visible when purchasing the van, the area suggested it was coming from the oil cooler/filter setup (a common area apparently?). New DMF & clutch installed with release bearing, new oil cooler gaskets, fresh oil and filter. Also Decided to renew alternator pulley/ tensioner as well as the crankshaft pulley.
Back on the road running sweet! After 2k miles since new flywheel I notice a hot brake smell a few miles into a journey to Gloucester, quick walk around the van to find the O/S/R Brake is binding. That's the plan for this week, maybe sometime this year I'll get round to doing the interior/exterior.
Future plans: Change 18's with low profiles to 16' steel is with A/T tyres Custom seat basis to lower seat height Replace lowered rear springs with standard height springs. 4k Video Downloader License Key Serial. Picking this thread up again as it almost comes round to a year since purchasing the Van covering 17,000 miles and counting! It's hard to remember all the changes in a year.
But I did strip the back out and made a temporary set up for last summer. Very quick and low cost change; to summarise used the old thin what felt to be plastic panels as a template and cut some new ones out of ply-board. Using some new and recycled wood, built an L shaped bed that pulled out to a double with two large storage compartments.
Very simple nothing flashy. I was very limited on time and spent most the evenings after work over a two week period to get a bed and cooker unit together ready for a trip around Cornwall.
But it all came together. Mechanical and exterior changes - Standard T4 wheels for comfort due to winter and lots of miles (not to mention buckling an alloy on a pot hole) - Raised the front suspension and replaced the lowered rear springs for standard springs. - Replaced the O/S outer C.V gaiter due to small split. - New rear section of exhaust due to corrosion. Excited for January 2017, the van is booked in for a complete body restoration and full re-spray, including removal of the windscreen all windows, and the door shuts!
Of course I'm staying with the yellow just not the same shade. Still longing for the all terrain tyres, and waiting to grab a set of the right steel wheels to match, a purchase more for spring I think! The interior is going to be stripped again, do the insulation, and ply-lining including carpeting the inside (not the floor). Add more interior lighting at the same time. One bug bare is the brake vacuum pump and its annoying tick! It's a costly unit from VW including the steel rod and that's with my generous discount due to working for VW aftersales for the last two years!
I'm sure I will get fed up soon and bite the bullet. I aim to improve on the photo uploads while being painted. Download Gavin Rossdale Adrenaline.