Yep, more of the same this weekend. We had hoped to fit the new window on Saturday but we have the wrong knock-on trim, so after much rushing around car parts dealers, and phoning suppliers, we gave up on that task, and switched to some jobs we’re already working good news is, we managed to finish the underfloor insulation and fit the new floor (after much deliberation, with short, self-drilling screws). And Amy has done most of the rust cleanup on the top of the van.
This week, I’ve been continuing work on the floor. Before we can lay the new plywood floor down, we need to fill the grooves with closed cell foam, and then add a layer of underlay. For this piece, I used the Soudal High Tack adhesive to stick down the foam.
Meanwhile Amy continues on the rust treatment, now fixing up the few dings and patches of rust on the outside of the van.
We didn’t have a whole lot of time this weekend, but made good progress doing some essential prep so we can get the new floor in.
Amy prepped the metalwork for rust treatment, and applied the POR-15 to all the minor inside patches of rust. It’s nothing serious, but we want to make sure all the rust in the inside is dealt with before we cover it in cladding or flooring, and never see it again.
I cut closed cell foam for the floor insulation, plugged the leaky body trim clips with silicone, and cut some of the plywood floor panels to fit inside the van, using the old floor as a template.
More cleaning today as we prepped the walls for the Silent Coat Sound Deadening mats. I bought the 40 sheet, 4m² bulk pack of Silent Coat, working on the basis of heavy coverage of the wheel arches, but only about 25% coverage for the main body panels.
Over the course of a few hours on Sunday, and a few more on Monday evening, we applied most of the mats.
With a few mats to spare, we’ve left the doors and roof as they are, until we’ve decided where we’ll be removing panels for windows and vents.
Meanwhile, Amy has been cleaning off more of the green goo, and revealing rust patches around the back door.
I spent the day on my hands and knees, cleaning up the oil, silicone and glue that the previous owners had split. A lot of it was on the floor lining, which I’ve removed, so no big deal, but plenty had seeped down under the floor panel onto the metal bed of the van, so I used paper towels, WD40, an old chisel, and lots of elbow grease to clean it up.
Taking the ply panels off the wall (just one wall for now) was a simpler task, and the walls themselves are in very good nick.
I did notice some water ingress at the bottom section of the wall, where the trim panels are mounted to the metal body with plastic clips that don’t appear to form a watertight seal. The problem has been detailed over on RadVanAdventures.com.
There’s no rust, and I don’t think it’s anything to worry about, but we probably should seal up those clips.
That’s all the work for today. I’m planning the next steps now, which will be:
- Deciding on a solar panel and where to mount it
- Deciding on roof lights and ventilation, and where to fit them
- Spec-ing out and buying some sound deadening mats
- Planning the insulation
We picked up the van yesterday from the dealer. Today it’s just me, as Amy is away. I started with the grotty jobs, removing the floor and the bulkhead. So far, no horrible surprises, though the previous owner seemsed to have butter fingers, spilling copious amounts of oil, silicone glue and McDonalds chips throughout the back of the van.
I was afraid it would be a nightmare pulling the floor up, but it wasn’t bad in the end. Tomorrow I hope I can get the ply lining off and clean up the muck.