26th February 2023 - Disco Transit Green Long Wheel base and Hi Roof Conversion

So we are hoping for another good day today.

As usual on a Sunday, I have Ebay SOLD Item's to process & Lynne n Michael have shopping to do, so it will not be till after lunch, before we are free to get in the van.

As eBay Sales were again very poor this weekend, I may be able to get in there earlier, I hope. 

And I can be getting on with things, till Lynne get's back.

Updated - Jobs pencilled in till Sunday

Boy has this list grown !!

I will delete completed jobs a week after they are finished !

Green - Completed job

purple - job in progress

Yellow - Job Description
Blue - new jobs added or not started

1. cut n fit bed foot board panel to passenger side of van - Finished

1A. Insulate food board panel passenger side  - Finished 

1B. glue foot panel board passenger side in place - Finished

2. cut n fit bed head board panel to driver side side of van - Started 25/02

2A. Insulate food board panel Driver side side complete - Finished

2B. glue foot panel board passenger side in place - Started 25/02

3. Measure & Cut front 9mm ply panel for bed - 

3A. Measure & cut storage hole in 9mm ply for bed - 

3B Fit & secure bed front 9mm panel - 

5. add extra supports to mount the sink. - hopefully be completed next Monday
6. Panel the bulkhead battery frame work.
7. Area next to passenger door, needs washing and going over with wire wool -  Finished!!
8. Finish adding sound proof pads - -  Finished!!

9. 35. Paint the Passengers side rear wheel panel -  

10. Clean old original panels - -  Finished!!

11. Insulate bed panels Passenger side - Finished

12. Insulate bed panels Drivers side - started 25/02

13. 

14. make base for bathroom sink 9mm ply - 

15. Mark out and cut inside bathroom wall 3mm ply - Finished

16. measure and cut 1st roof panel 3mm ply - just some clips to add
17. in 1st roof panel, cut holes for ceiling lights. - DONE
18. run light wires thru roof frame. - Done 12 volt & 220 volt lights & wires. Entrance

18A. 2nd panel run light wires thru roof frame. - 

18B. 3rd panel run light wires thru roof frame. - 

18C. 4th Panel run light wires thru roof frame. - 
19. Finally screw roof panel into place. - Panel clips have arrived
20. mount bathroom sink extra mounts - 

21. install sink tap & waist pipe - REMOVED to install wall boarding

22. 

23. re-assemble the framework onto raised toilet area - 
24. measure and cut 3mm panel for behind the toilet -  Finished!!

25. insulate the panel and fix into place -  Finished!!

26. - put bathroom door frame back. - 
27. remove grill from kitchen unit and repair and put back - Removed, Lynne has started washing it.
28. water pumps screw to back of kitchen unit - 
29. remove sink and drainage board - 
30 buy some sealant gaskets for kitchen unit and install - arrived - not yet ready to use
31. refit cooker & sink & drainage board -  
32. move kitchen to its final location - Now needs Bolting in place (25th/02)
33. bolt the kitchen in place.
34. Glue extra Insulation in the inside of the drivers side rear wheel arch panel. - Done

35. Paint the Drivers side rear wheel panel -  

37. sand back to top of the bathroom wall, so panels match the upright - Done

38. sand back to bottom of the bathroom wall, so panels match the upright

39. Rear Drivers side sound proofed bottom half -  Finished!!
40. Added DODO insulation and more sound proofing -  Finished!!
41. Re use the original Ford Cover and clip/bolt into place -  Finished!!

42. needs sanding and prepping for painting white - 
43. Paint the panel - 
44. rear passenger side lower half needs to be washed. -  Finished!!
45. sound proof pads need adding -  Finished!!

46. DODO sound/insulation needs adding -  Finished!!
47. clip/bolt back original Ford panel - See 19th Febs Update
48. needs prepping for paint

49. Paint

50. measure and find best position for bed. - DONE
51. Start making frame for the bed.
52. add mount points to transit frame for bed frame.

53. Order new mattress - NO NEED AS MANAGED TO GET OLD ONE TO FIT
54. Cover Mattress to protect it.

39. Kev's workshop - Make some brackets and install roof rack on roof of transit. (Funds ring fenced) - Booked in on Tuesday 14th Feb.

39A. Kev's workshop - If time and funds allow, get water tanks installed underneath and plumbed into the back. (have some funds available but I know it will not be enough!) - Booked in on Tuesday 14th Feb.

Double Bonus job, to have worked out and cut the bed frame & have it mounted!

Our first job today is to spray glues this panel and the board that will be covering it up

And as this board is a bit warped and one of the frame rails sticks out too far, we prop the panel in place, to give the glue a chance to go off.

And finally we start on the actual bed frame!

This off-cut of 3x2 has had one end cut out so that it sits under the kitchen unit.
And will become part of the wheel arch cover and base of the bed frame.

Again Lynne is doing all the measuring and marking.

we have jigsawed the bed front out of the 9mm ply board
and Lynne has marked the passenger side rear wheel arch, ready for me to cut out in a bit

The drivers side rear wheel arch is marked out ready for me to cut in a bit.

But before I cut, we need to raise this board up.
So we put all the 3x2 timbers behind the bed front panel
and at the top we put the long side tide bar

( I must get all 3 measured, pics taken and get them listed)
So we can lift the board up onto them.
Which will make cutting low down a lot easier for me...

A very unwanted enforced break is needed due to me having an accident yet again!.

rear wheel wells are cut out.

All need sanding back as we fit the board in place.

Nope does not fit !

So I alter the profile and cut n sand the window side 

Then we cut out the excess from the front bed panel, which will make it a lot easier to manouver around.

This is not the set height, we are looking at removing another 7cm's to lower the access to

the bed a lot easier, but first, We need to get the frame built and the mattress down and make sure it fit's, before we look at making this side lower.

Altho a lot of sanding still to do, it looks a lot better.
The high part will be bolted to the kitchen and denotes the boundaries, between teh Kitchen and the bed areas. 

As we get closer, I have to cut a huge chunk of this end,

so that we can still open the window and the ply board is not touching the window

Now this end is withing 6" of where it needs to go, 
We can now cut out the shape of the side of the van

We are so close now, it is just a case at looking at where the ply board is touching the sides of the van and cutting & sanding 

So close !!
Then we realise, that the edge of the ply board lines up on the pillar, not here as we thought ??

Finally some 3 hours later after our first attempt to fit this board in place, we have it lined up to the millimetre :) :)  

But it is 6.30pm and it is time to go and start dinner.
And that is were we end for today................