2001 Sprinter 411 build from scrap Murvi Morello!

[Mickandsej]

But I’m also fitting two 100w solar panels so best cut a load of templates too.

 

[mrmoosehead]

I did similar to you but used layered mastic. There’s now a company that makes the Ridge Inserts, (not sure if they fit most vans) they should be available on EBay Search “1 Pair Filling Profile Roof Vent Fiat Ducato Citroen Relay Peugeot Boxer Camper”

Basically what I made myself

 

[Mickandsej]

Went to a local metal stockholder this morning and now waiting for a quote on fabricated panels to blank off rear side windows. Glad I did (subject to price!!) got really good advice. Going for ally, will brace with battens internally. Helps reduce tail loading on the van. He’s obviously done this before as he tried to trap me with all the rookie errors eg drumming, condensation, is your van solid before you start etc etc, all in a friendly way but a top guy.
Panels will be cut to size (has measured the van) and laser cut radius corners.

 

[egg-fried-rice]

Roof Vent Seal: I think either are fine. But I have found that some plastic expands badly in the heat and van roofs can get exceptionally hot in summer so I wouldn’t layer plastic.

I cant fault mastic if it’s used correctly. It compresses when the vent is screwed down and forms to any contour. It also makes a water tight seal that should last for many years. However, it isn’t visible as the mastic is hidden under the vent and the outside edges of the vent are sealed with sika-flex. A submarine commander once told me that my roof vents are more water tight than anything the navy has in its fleet.

 

[mrmoosehead]

A submarine commander once told me that my roof vents are more water tight than anything the navy has in its fleet.

Don't try submerging it though. All those holes in the floor...

 

[Mickandsej]

I’ve got some sections of upvc fascia which I would guess are designed with heat in mind? It’s a nice day today so I’m going to get the ladder out and scrub the roof with plenty of TFR then start marking out.

 

[Mickandsej]

Spent the morning up a ladder with a warm bucket of TFR mix, scrubbing brush and sponges. Managed to get all the green barnacles off the roof. Ready to key and paint the top (unseen from ground level) in Matt white hammerite. Then I can start the roof jobs…
Before

 

[Mickandsej]

After

 

[Mickandsej]

Got the roof lining out today. As expected a fair bit of condensation especially behind the alloy sheets. They won’t be going back in now! Found some sturdy steel channel was supporting the roof lining, will re use the ply that came down. Also found the roof hoops are right where I didn’t want them so more work framing the roof vents. But worst of all the centre roof seam has rotted a bit and leaks, as I discovered yesterday when washing it. Not a big deal but another job at the front of the list to deal with. Luckily got a new bottle of Aqua Steel..
Anyhow today’s discoveries have changed the layout slightly, now I’ll be fitting the kitchen/shower ceiling right up to the second from back hoop, makes it smaller sections and easier to handle. The alloy sheets for the window blanks are going to cost £200 tailor made so that’s settled the plans behind the axle. The cant rail is a separate box section from the roof so ideal for wire routing.
I’ll think about the middle and front when all these shenanigans are over!

 

[Mickandsej]

Just hope I have some roof left when I take a mop to the seam tomorrow…

 

[Mickandsej]

Finished removing all the decals and started compounding the paint to clear all residue. Will need another light compound in the spring but looks nice for now. DA mop is bloody hard work especially when up a ladder but needs must!
Wire mopped and rust treated the roof seam.
Wish I had the energy and weather to paint the wheel rims (no not the centres…)

 

[mrmoosehead]

Finished removing all the decals and started compounding the paint to clear all residue. Will need another light compound in the spring but looks nice for now. DA mop is bloody hard work especially when up a ladder but needs must!
Wire mopped and rust treated the roof seam.
Wish I had the energy and weather to paint the wheel rims (no not the centres…)

Scrubs up nice.

 

[Mickandsej]

I think that’s it for a week, I’m on Days til Thursday, then I start my permanent late shifts so will be able to crack on with it.
I think I’ve just about done all the prep on the roof, next job is to spruce up the top skin then fit the vents and solars. Best rest before I start cutting big holes in it!

 

[Mickandsej]

Scrubs up nice.

I was lucky, it’s not clear coat, mustn’t scrub too much though!

 

[Mickandsej]

Still too cold to paint, so got on with more preparation. I helped clear a neighbour’s garage recently and grabbed loads of timber, upvc and some useful metal trunking.
Made the Fiamma frames with oak batten, upvc loosely cut for the slivers, profile gauge tested. Going to plan a day of cutting and sealing soon enough.

 

[Mickandsej]

Slightly jumped the gun with ordering parts today. But as I’m installing the Solars soon I thought I’d get this inverter and test it whilst fitting the van out, charging tool batteries etc. It’s a big unit but was only £3 more than a 2kw/4kw peak equivalent.
I’ve also already bought their 8kw diesel heater, it’s got an integral tank so easier to fit and use through the build..
Will update as I test them.

 

[egg-fried-rice]

Slightly jumped the gun with ordering parts today. But as I’m installing the Solars soon I thought I’d get this inverter and test it whilst fitting the van out, charging tool batteries etc. It’s a big unit but was only £3 more than a 2kw/4kw peak equivalent.
I’ve also already bought their 8kw diesel heater, it’s got an integral tank so easier to fit and use through the build..
Will update as I test them.

It looks like a budget inverter if you don’t mind me saying. It probably won’t charge iPhones and some Laptops. From what I’ve seen these appliances need Pure Sinewave not Modified Sinewave. Check what appliances you want to use on it.

£139 is cheap, (a bit too risky for me) to give you a comparison I paid around £300 for a Victron Pure Sinewave and it’s only 800watt with a peak of 1000w but I‘ve never needed anything higher than 800w, not even once. (my personal thoughts are that any appliance that consumes upwards of 1000w is going take a big chunk out of your battery if used frequently). Cheap inverters carry a risk, Greg Virgo’s (Popular YouTube Campervan builder) lasted about a year then went with a loud bang and puff of smoke, a few others overheated to the point they nearly combusted.

As regards the 8000w heater, check if you need this amount of heating power. I’ve seen a guy with a 5K version in a medium size van and it blows him out, it’s that hot. He regretted not buying the 2K version as he can’t get it to run at a low temperature constantly, without having to keep switching it on and off.

I am told that 5K and 8K heaters are the same but one has more pumping capacity ie it uses fuel faster. I don’t know if this is true but it sounds feasible. They are ideal on boats (a lot larger than a van) but unless your insulation is poor 2K should make a van warm as toast even on the coldest day.

If price is an issue then take a look at the Canadian made The Kreiger 2000 Watt Inverter - £169.00 on Amazon it’s a good entry level inverter.




Hope this helps in some way.

 

[Mickandsej]

Thank you, I’ll see if I can cancel the order. Re the diesel heater it’s a bit hefty but it doubles up as a garage/shed heater (suitably vented) so still has a use!

 

[Mickandsej]

Although I’ll add that the thinking behind going ‘big’ was to assist with the surge the microwave oven creates. I’ll be starting with the two leisure batteries I already have, charged from split, solar and 230, it’s just over egging the spec for occasional off grid use such as tv, kettle, toaster, microwave. I’ll still have gas for hob and water.
I plan to put the inverter in the large box under the bed with plenty of cooling vent and an isolator, and build a separate ring main from it with just a few sockets suitably marked up. I can’t afford a new fridge and my 3 way fridge is a very good one, so will install no gas for it (too many holes to cut!) but 12/230 mains/230 inverted. Don’t plan on off gridding in the winter.