27th February 2023 - Disco Transit Green Long Wheel base and Hi Roof Conversion

Which means we get rid of a lot of the completed jobs from the Too Do List below.
Which will soon have some new jobs added as the completed jobs are done.

We have had a great weekend in the back of the transit,

not in loads of jobs done,

but have certainly made an impact visually.

There are still loads of jobs started, some are on hold, as waiting on funds to buy the parts, others, I just cannot get to at this stage.

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 25/02

1A. Insulate food board panel passenger side  - Finished 25/02

1B. glue foot panel board passenger side in place - Finished 25/02

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 - Started 25/02

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!! 25/02
8. Get MDF from old bed from green shed and cut to fit the bed frame - 

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

10. need some material for bed header cover - use some DODO insulation as filler - 

11. Insulate bed panels Passenger side - Finished 25/02

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

13. inside kitchen cupboard by bed, need strengthening, so we can bolt the kitchen and the bed together -  

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. 
18. 

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. 

25. 

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 25/02

35. Paint the Drivers side rear wheel panel -  

37. 

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

39. Rear Drivers side sound proofed bottom half -  Finished!! 25/02
40. Added DODO insulation and more sound proofing -  Finished!! 25/02
41. 

42. needs sanding and prepping for painting white - 
43. Paint the panel - 
44. rear passenger side lower half needs to be washed. -  Finished!! 25/02
45. sound proof pads need adding -  Finished!! 25/02

46. DODO sound/insulation needs adding -  Finished!! 25/02
47. 
48. needs prepping for paint

49. Paint

50. measure and find best position for bed. - DONE 25/02
51. Start making frame for the bed. Started 25/02
52. add mount points to transit frame for bed frame.

53. bring mattress down, when bed frame is made
54. scobby doo's for blue cover for 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!

Using this 9mm ply off cut from Yesterday, 

I mark it up at about the right height.

And clamp it to my work bench

The Jigsaw, soon makes light work of cutting the 9mm ply

I have not planed it yet,
and it will only go in this far!

So out comes the planer and I soon make it short work.
As you can see I made a 2nd straight line, as it was a bit tight sliding in.. 

Whilst the 9mm ply board, is on the bench.
I mark in 1 1/3rd inches for the inside
(shaky hands today, makes drawing a straight line difficult !)

This is were the 9mm ply board will be going.
I was gonna cut the top worktop back, but decided against it.

So we needed something to fill this gap, as the kitchen unit and the 9mm ply bed front will be bolted together.

And with a few gentle taps with the rubber mallet and a piece of wood, in it goes...

Now just gotta add a piece inside the kitchen unit later on,
when we are ready to bolt it all together. 

Using an off-cut of 3x2 I trim it to fit on the floor against the bed side.

I cut a 2nd piece to sit on top of the drivers side rear wheel arch.

And then using another piece of 3x2 off-cut, I trim it to fit as an upright.

This will be screwed to the bottom piece and the inside 3x2 baton, and will eventually form the framework to cover the wheel arch

Time to start assembling all these bits together..
That's the floor 3x2 screwed to the upright 3x2

Next we screw on the top 3x2 of the wheel arch

Time for  a quick check and it all fits as it should..

My bag of small off-cuts...

I am sure, I will find what I am looking for in here

Yep, I have the 3 3x2 small off-cuts I want, and cut them down to 5cm.

And I screw the 3 3x2 off-cuts to the other parts I have screwed together 

and then I screw on the other top 3x2 to it all

And it fits perfectly first time :) :) 

No tweaks needed.....

1st of the top rails are measured and cut.
Then have the holes drilled in them, as this one will be using the bolt holes for the panel combined.

I just need to get the right length when I cut the threaded bar. 

Now I remove all the bolts that are currently holding the 3mm covering.