Ducato build

[BikerBoy]

HI
In the middle of january we bought L4 ducato. 7 weeks of build pass. (In a meantitme van week in garage - injectors replacement ) During this time we insulate van, replace floor, fit floor vinyl, prepare wiring looms, make main panel templates, fit ceiling, stick headliner and few smaller jobs was done. Generally on time with plan.
I will try to post pictures or movies maybe will be kind of inspration or help

 

[BikerBoy]

Hi
Thanks for a support
We bought van from somebody who abandon conversion on early stage
floor - i have to do it again , partial insulation - i have i take it out , some wires -taken out i will reuse conduit
pros - swivel plates, second row doube seat - we sold
It will be continental layout
I try to work over van 2 hours every day , but weather was my enemy till now.
My bettter half already choose boards color and i hope to buy it tomorrow.
Here is link to movie how i fit floor vinyl (if anybody are interesting in such a boring stuff)

 

[egg-fried-rice]

Thanks for sharing nice to see your build. I have a similar vinyl floor but I was advised not to glue it down as it’s incredibly difficult to remove if you have to. I am not saying glue is wrong, it’s another way of doing the same job, instead the purpose of my comment is to say that without glue the floor can also be laid stable and secure (zero lifting).

Nice to see, keep us updated (we like images).

 

[BikerBoy]

of course always you have few ways for doing same things ,
like i wrote earlier time to purchase boards
on saturday i bought lightweight plyboards, (140 GBP per piece)
Today I cut it for smaller pieces ( to store in living room ) and cut out main panels
also final step with raised floor in front of van means trimming vinyl

 

[BikerBoy]

today is a parcel day
i get
aluminium corner profiles
shower tray
tambour door (just one to test )
i waiting for ordered
aluminum rectangle sections , foamex and modesty block

Anybody have a good source of ABS edging?

and for some doubtful entertaiment movie from main panels cutting

 

[BikerBoy]

stage A are done so
summary of jobs done in 43 labour hours

 

[BikerBoy]

cut out theford toilet door

 

[BikerBoy]

terrible weather...
anyway today afternoon I fabricated two aluminium brackets
always one step forward

 

[BikerBoy]

part of epic fight with new cab headliner with small shelf
this is bottom part of it

 

[BikerBoy]

inside van (of course a lot of tweeking have to be done)

 

[BikerBoy]

inside van (of course a lot of tweeking have to be done)

full (nearly) process shown in video

 

[BikerBoy]

pretty few hours of work over "magic" bathroom wall but nearly ready to fit inside van.
elliotis pine ply 12mm covered 2,5 mm orange pcv. Holes: lower for sink in drawer, top for tambour door cabinet. These round holes are for weight reduction . Of course sink drawer are much deeper (40cm) then "wall" (20 cm) so will slide under bed frame (if I design everything properly)

 

[BikerBoy]

orange bathroom wall inside van

 

[BikerBoy]

short weekly update to many things start non of them finish
but I'm behind schedule

 

[mrmoosehead]

short weekly update to many things start non of them finish
but I'm behind schedule

You have a schedule?
I just work on mine when i find the time

 

[BikerBoy]

yes I have full project schedule, BOM etc.
of course i not going down to the smallest details
what was underestimated (by me)
problems with materials handling -ply (and other) sheets i have to buy in small quantity no place to store
and weather was too cold
3rd - hard to count time to solve problems with new bespoke design

 

[BikerBoy]

panel edging with 2mm thick ABS edgeband and not proper tools

 

[BikerBoy]

panels from pictures in previous post are already fitted

 

[BikerBoy]

countertop (one of three)
from scrap wood

 

[BikerBoy]

To tell truth is simple ,maybe time consuming but simple.
This exotic wood it's truck bed light wood it's oak probably architraves
All u need it's a table saw and orbital sander (I use also band sander)
Cutout for round sink was done with router (on second countertop)
In my opinion everybody can fabricate such a nice countertop