29th January 2023 - Disco Transit Green Long Wheel base and Hi Roof Conversion

Right lets see if I can get much done today!.

Lynne hit me tonight that she is on holiday in 2 weeks time!!
But will we be ready even in a very basic form ??

Back in the Transit bright n early this morning, and this mess is today's area that I will be trying to complete.

I am not expecting to covering boards to be cut today, as I need to go down the workshop sometime and find the jigsaw and I hope some blades.

I start with a bit of a tidy up in the bathroom, as I need to get down and take some measurements.

I sit n think and re-look over what I planned to do and it dawns on me it will not work!
But not everything from yesterdays efforts are wasted.

I need some small off cuts from this 9mm ply board.
I do not know if I will use them, but I feel the need to try and see what happens...

I purposely left the 9mm board in place in the bathroom, as I wanted to create a vent for the battieries & the bathroom.

Right this 4x2 is too long, after a re-thing from yesterdays efforts, I know realise is not gonna work!
I just have to sit n think a bit and let the plan form in my mind.

I wonder if the air vents could be extended all along the battery compartment ?

My mind is already elsewhere, and altho I am trying this out I soon discard it!!

Something clicks and an idea is formed, I quickly sketch it down before I loose it, but barly manage to do that and its gone :( 
But I think I may have enough saved.

Th elong 4x2" that is now too long for what I want is laid down on the existing battery frame and measured.

And I grab the off cuts, I was gonna cut down yesterday 

And I dry build the front frame.
And I start to screw it together (not glued at this point in case I need to take it apart)

And it is finally in place. Still not 100% right.
I am not sure whether to add an upright in the middle as the 9mm board should be more than enough strength.
But it is level with the rest of the frame work.


I had forgotten to remove 9mm for the bathroom wall panelling, so I have a slight over hang near the door.
But I may leave this, as I am planning on moving the inverter that is above the cabin (taking up valuable storage space) and have it installed behind the front panel, facing the door).
Just so we have power if we ever install one of those sliding roof things...

That is the top spacers all cut, plus 1 for a spare

Just going thru the very basic notes i scribbled down, before they disappeared from my brain.

Yep that is were the 1st spacer will go 

Nearly forgot to add the 9mm board, so I have enough space when I board the bathroom.

All screwed in place, with the back rail propped up

Time to finish drilling the rivet-nut holes.
But when I go to use the Rivit-nut tool, I cannot use it!.

So I phone Lynne & Michael to see if they can help me...

Michael uses the Rivet-Tool for me, altho 1 is still a bit loose.
So I decide to cut longer 6mm threaded bar and screw it thru the bulkhead and Lynne managed to get washers n nuts on. 

With the aid of Lynne's eyesight and me wielding a rubber persuading tool, we get the rear battery cover in place and bolted up.

We have done the nuts up as tight as we can and I hope that it has crushed the Rivet-Nuts even more.
I will buy some 6mm Domed nuts for both sides at a later date (when funds permit).

Now it is time to work out the hinges.
I had decided, if I need to work or remove the batteries it would be better if we can remove the top/front in one piece out of the way.
So i am using these detachable hinges, I would like to use 3, but in the past have never managed to get 3 to work as they should, so we will see.

So I mark out the centre hinge position and then I think how am I gonna do this, as I do not have any chisels ??

I need to go for a wash n change of trousers, whilst I am sipping my Hot Chocolate, the thin belt sander comes to mind, so I head down the workshop and grab it with some spares and head back into the transit.

Ok it is not perfect, but it will do the job, and it will not be seen unless we have the lid off.
I keep sanding away, till I have the length and with that the hinge will sit level and square.

an din it goes and is screwed in place.

I made a mistake on the 1st cut for the hinge to hide into!
As us can see it is the wrong way up ???

So I use the other side and mark the area to but out again and hope I have it right this time.

That's better. Now to do teh same to the other 2 bits of timber

And finally it is all done.
Will the hinges work as planed....

I wait for Lynne to come out............................

And yes it all comes off easy enough :) :) 

But it will not go back easy, so I remove the middle hinge and it now works flawlessly...
and that is were I call it a night, I can barely stand let alone move.
So for me it will be tea and bed...........