Today has not been the most fulfilling of days. I spent half the morning on the phone trying to sort out spare keys and the correct trim for the new window we bought. Amy was swapping materials at Screwfix. Then we tried to figure out where to route the conduit to allow for wiring up the solar panels and any 12V electrics in the van — which is tricky given that we haven’t decided where any of that is going to go. Then we fixed more rust, cut more Celotex insulation boards, sprayed more expanding foam … the same as we’ve been doing for days now it seems. We’re getting through cans of foam like there’s no tomorrow, and I can also tell we’re going to have to swap some of the insulation boards I bought for thinner ones, as the cavities at the back of the van are much shallower than those at the front.
I did manage to finish one small job, which was to improvise a raised platform for the dog to sit on behind the cab seats so he can go in the back comfortably while we’re driving. And Amy had success fixing one of the rear door magnetic retainers on the side of the van, which was poorly seated and letting in water. We want to go away in the van for a few days at the end of this week, so we’re just trying to get it fixed up enough to do that.
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.