Sprinter 411CDi Murvi build

[Mickandsej]

Today I finally broke ground so I thought I’d shift my thread away from Introductions!
First decent day I’ve had off work, was going to fit the Fiamma awning but I’d ordered M10 not M8 CSK bolts…
So I got brave with the jigsaw and started fitting the first 3 Fiamma vents. The 4th will be a different job as I’m removing an old skylight.
Had prepped oak frames earlier on, fixed with screws only as I thought I’d rather trace any leaks directly instead of gumming the frames in, also makes for easier removal in the event of future damage.
Used my vinyl wrap magnets to secure an old shower curtain to catch the swarf, cut the holes with a step drill and cordless Worx jigsaw, cut 9mm upvc fascia into strips and Sikaflex’d it all in, then screwed down the internal bezels to set it all off. Will sculpt a decent bead around it all tomorrow and then paint the roof ready to fit the 2x100W solar panels, DAB aerial and Status 355 tv aerial, then I can start the Dodo Mat and roof insulation.
The 280 vents are offset as the kitchen cabinets need a different set up. Front vent is awaiting a CNC sheet to blank off the 50x35 hole for a new 40x40.
Finally after a month of ordering, design and hours of preparation and tear down I’m out of the ground and building - deadline for useability is just 6 months away….

 

[Mickandsej]

Fitted the last Fiamma vent today, then first coat of Ford Olympic Blue enamel on the top of the roof.
But I kept stepping off the wrong side of the step ladder and got a bit bruised so no pics today, packed everything away and second coat tomorrow. Off to see Live/Wire AC/DC tribute band tonight…

 

[Sandbagsid]

it’s surprise ing easy to forget we’re your At on a ladder

 

[Mickandsej]

it’s surprise ing easy to forget we’re your At on a ladder

A bit embarrassing though, you wouldn’t think I used to be a Fireman….

 

[Sandbagsid]

ha ha that’s even better, ex fireman falls of ladder. Glad you’re ok though.

 

[Mickandsej]

Done most of the top now, just need a good day to lay another coat of enamel, and fit a DAB aerial for the rear stereo.
Belt and braces approach to fitting the solars, not yet wired in so wrapped in bubble for now.

 

[egg-fried-rice]

You aren’t wasting time.

Bolting the solar to the roof will put your mind at ease when driving through gale-force winds (M62 Yorkshire comes to mind). I know a lot of people use silkaflex bonded brackets which are probably perfectly adequate but for peace of mind you can’t beat the old nut and bolt.

As for the solar panels are you wiring in parallel or series? One guy claims he gets a bit more out of a pair wired in series, can’t say how true it is but maybe it’s worth a try as every drop counts with solar (easy to change later if you want).

 

[Mickandsej]

Thanks, I’m doing parallel, as are the batteries. It’s overkill again as we only have one off grid weekend each year and that comes with hot showers and we use a Halfords cooker.
Externally I’m using sealed rivets and a dab of Sikaflex inside the van on them. Will add more later on but set it all in place for now. I think the roof vents will take some of the pressure off the mounts at speed.
Got the Fiamma brackets on now, and fitted the reversing camera, a bit disappointing as the resolution is poor but it’s functional and complies with insurance

 

[Mickandsej]

Been a busy week at work so bugger all done on the van. Waiting for a neighbour to help me lift the awning up, need a day to declutter the back of the van and tidy up tools and materials. Start my new shift pattern on Monday so will be able to plan and do a bit each day now.
In my head it’s all going well but I’m crapping myself over the first fix electrics - what will I forget????

 

[BigAldo]

In my head it’s all going well but I’m crapping myself over the first fix electrics - what will I forget????

Just run extra cables and leave them curled and hidden at strategic places around the van, and the other end adjacent to the fuse box. You WILL find a use for them further down the line. I used 2mm sq conductors which covers most eventualities. I have used all the extra cables now, mostly for additional USB charging ports.

 

[Mickandsej]

Actually I’ve got hundreds of metres from the old van to re use, but I was thinking of laying 16A 7-core from the box for add ons.

 

[Mickandsej]

Started the Dodo matting today. Began at the back and worked forward, I was a little bit careful with usage at the start but soon realised I’ve actually got loads of the stuff. 2 boxes of 40, so started covering more as I went. Will patch in the rear with off cuts. It’s good that a single box has done the entire roof, with the windows there will be a lot left over for below them.
Just having a cuppa as I’ve got cramp and a stiff neck!
Will slash the indents to ensure no air gaps are left. Don’t want it sweating later on.

 

[Mickandsej]

I can recommend the Dodo metal roller, it makes it easier to see where I’ve rolled as it’s got a textured wheel. Worth the extra couple of quid.

 

[Mickandsej]

It’s backbreaking work but has to be done at the outset doesn’t it! All these YouTubers with their Cellotex and squirty foam tell another tale. It’s surprising where the money goes, I’ve now spent over £1k just prepping the roof, adding skylights and solar, tv aerial and deadening, insulation and fleece. And I’m nowhere near trimming it out yet…

 

[Mickandsej]

That’s enough for today. Will finish the roof hoops, wrap the box section above the windows and attach the fleece another day…

 

[Mickandsej]

As Jeff Beck so eloquently put it….

 

[Mickandsej]

Fiddly fiddly job this is. Final recommendation - wear thick rubber gloves, or it’ll get all over your paws. Also do not underestimate how quickly this stuff blunts your knife! Don’t even think about using scissors it’ll triple the time you spend removing the backing paper. When doing slivers cut a load in one go.
And take regular breaks or your neck will jam over at an angle!

 

[Mickandsej]

And do it at the start of the build. I can’t imagine how you could do this properly in anything other than an empty shell.

 

[egg-fried-rice]

You’ve got yourself a Faraday Cage that no mobile phone signal could possibly penetrate, nod, wink.

 

[Mickandsej]

I’ve been itching to get this bit started…