Time for an update.....

[richbaker78]

Cheers easy does it , I'm getting closer to paint .....just a few more things to fabricate.....

[richbaker78]

bike rack finished - these side supports stop the bumper flapping about over bumps and at speed.
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didn't want to make an unsightly support so made a ladder to attach bikes to when on the rack. this doesn't make contact with the bodywork at all, is removable and also I wanted one that followed the vans contours and is adjustable in length.
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then onto the roof bunk system

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[richbaker78]

roof bed finished - will have more boards than this - amazing how weak the roof was and how badly cut out by dormobile.
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I didn't want a fabric headlining so I painted roof black as was only spare paint I had to seal it...then painted it with PVA release agent.
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so we could use the roof as a mould for the headlining - JP in action...first time we had done this so learning all the time!


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fortunately release agent worked - I was worried it would be stuck forwever!
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end result....sides and back to do now

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[richbaker78]

got the back part of roof done today....
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[richbaker78]

trimmed to size and fitted FG headlining - obviously not finished but I wanted to get this trial fitted pre paint so I can build on it in future. It massively improves head room and has a lot more integrity than original set up - so insulation behind will be easier as will mounting lights etc. also I really like the detail of the little rim which mirrors the outside too.

front

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back

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still sides to add....but you get the idea

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also finished off the battery/ecu boxes

[img][url=http://www.flickr.com/photos/95888253@N03/11391677495/][/img]

[Superleggo]

I like the head lining system. it should give you a neat finish

[Obonobo]

Wah, that headliner-construction-method is really nice!
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Greetings from Sietze
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Driving a '75 Bay with a EJ22 '93 and 091 6-rib box.

And it's a long time since it looked anything like this!

[easy-does-it]

.. when i first saw what you were doing i didn't think it was going to work..

But damn.. that does look good.
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'76 bay going superfly TDI

[richbaker78]

Cheers for the comments, it's so strong it doesn't need any middle supports:) I'm intending to finish it with the sort of stuff you find in modern cars, it's cheaper than buying a new fabric one too. hopefully the Xmas hols will see all fabrication done. 2014 the year of paint !!

[richbaker78]

I wanted metal 1 hole headlamp rings that actually fitted....although aftermarket ones are available the quality and fit is not great so got a pair of genuine 3 hole ones and welded em up, and trial fitted to van whilst I was there to ensure a good fit. I will get them chromed


also added the sides to the headlining and trimmed it up....pics are pre trim


also added an audi q7 centre console with map light and cabin lights.....


which needed some sides - I made moulds from some celotex - its easy to shape with a knife and sandpaper and free from a skip.

[Kai]

Owewee, I'm liking those headlight rings. I've got a set of single hole rings and they are a rubbish fit. Certainly going to think about stealing your idea
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Think......

Don't sleep and drive!!!

[richbaker78]

couple of minor but time consuming updates....
finished the surround for the interior light....


and finished fibreglassing the sides to the roof where it goes up into the pop top


then focused on a job I started ages ago....making a tensioner for the air conditioning pump that provides air for the air suspension - i used a Scooby legacy steering pump tensioner, removed the pulley and replaced with a mk 4 golf cambelt pulley I had left over from a cambelt change.



and fitted - you can just make it out on the bottom right side (the only place it could fit!) I also made a simple tensioner for the alternator which pushes off the chargecooler mount