so in this video i'll be going through the van conversion that we did unfortunately i
didn't film the whole thing but luckily my partner filmed the start and i started filming at the end
so this conversion is for a vw caddy maxi so at this point we had already stripped the van
down cleaned it outed some of the rust points and and done touch-up paint so we'd already insulated
the wheel arches and the sliding doors and at this point we're just doing the wall panels
so the process for the wall panel was to strip down the wall panel clean it with double-sided
sticky tape onto the wall to allow the recycled bottle plastic insulation to stick to it we then
cut the bottle plastic to the size we needed stock it to the wool and use aluminium tape to hold it
in place we then covered this with the thermo wrap and stuck it down again with the aluminium tape
once we had done one wall panel we then moved on to the flooring so again we then cleaned out
the whole of the flooring and wiped it down as it been a few weeks since we'd first done this
so we cleaned down the whole thing we then take round all the edges to make a seal around the edge
because you're worried that if it did rip there might be moisture that collected on the edges
and that could lead to rust so he taped all the edges thoroughly to make sure it had a good seal
next job measuring the fermi wrap against the plywood and cutting it into the right shape
we use double-sided sticky tape to help the thermo-wrap stick to the floor
and roll it out into place we then stuck this down and sealed all the
gaps with aluminium tape i tape it all up with the aluminium tape and then i can put the ply back on
once this is complete we then finished off the installation of the walls and the doors once all
the doors and walls were done we then moved on to the roofing for the roof we used van insulation it
was actually just called van insulation we bought off ebay this is great as one side was adhesive
and the other side had a silver finish to it so this gave its own thermo barrier so we cut this
to shape and stuck it all into the roof panels so once this is all done we taped all the gaps
and thought we should use the leftover recycled bottle plastic that we had so again we cut this
to size use double-sided sticky tape stick to the roof and aluminium tape to help hold it in place
nearly done half the roof just need to tape up the sides and then we can slap slide the
plastic roof back on once we had done this we then put the roof back into place
and that was pretty much all the insulation completed so i know this isn't a great way
to explain it because we didn't film the whole thing but it just gives an insight i'll add the
processing description so you guys can have a read so once you've done all this i then added
a few extra pieces to the vans so this here is the curtain rail i've installed so i've screwed
a piece of wood into the existing bulkhead screw holes and then i've attached a plastic rail that
the curtains can then attach to and slide along here's a little demo of the curtains
so i also added a bit of a van insulation into the footwells as well it keeps it a bit more tidy and
just gives that extra layer of protection i also made use of the old bulkhead by cutting out the
existing sides so it'd fill up the trim and then i attached the side of the curtain to this as well
so here you can see how the curtain has been attached to the plastic edge
i use double sided sticky tape to do this so here's the inside of the van
looking at the cab so i also painted the roof white as well just to get rid of the
industrial look uh opens up a bit more and makes it nicer so then we bought some laminate wood
flooring from home base it was quite cheap so it's 12 pound a pack so we bought two packs to cover
the whole floor i didn't have the right tools to do this so i just did it by eye and it actually
turned out quite well so i cut the first piece to the edge and then continued to work from one
side to the other connecting the floor as i went to ensure it will fit perfectly once it is all
fitted i then took it all apart again used some wood glue and relayed it once the glue is in place
and put a load of weights on top of this and left it for 24 hours this then stuck really
well and the floor is completed so at the moment we've still got the plywood to add on
to the sides this is what the interior looks like with the insulation and the thermo wrap
i'll be showing you how to install a ply lining kit for your van i found this kit
on ebay and i'll uh put the seller in the link so you guys can buy the same kit if you like so once
i ordered the kit it came within about two days which is ideal and this is during the kovid 19
lockdown so it was exceptionally good service from the company it came in a couple of cardboard boxes
i didn't order the full kicks i didn't need the roof or the flooring so i just got the
side panels door panels and the wheel boxes so i unloaded all the parts into my garage to make
sure they're all there and you get a selection of screws and fitting instructions as well
so to give me if i remove the panels i'd already put on the doors
so i took all the plastic clips out so i was ready to install the ply lining
so it's pretty straightforward to fit as i've insulated the van i took the thermo wrap
off the panels already had and stuck into the bottom of the plywood panels for the doors
i then started off by installing the first panel onto the side i'd recommend having two people to
do this as the van is curved the plywood fits as you push into place as it bends it then curves the
to the wall and that's what makes it fit so if you put it just straight on it won't fit so definitely
recommend having two people so this will fit fines as the company marks that where you need to screw
so just go ahead and screw the self-tapping screws that come with the kit into the van so
unfortunately my drill broke as we were doing this so it took a lot longer by hand but it's still
achievable you can do any of the panels however you like i just decided to do the side panel first
then went ahead and did the door panel again making sure it all fits and just screwing all the
screws once this is all complete i moved over to the other door panel and followed the same process
again it's pretty hard so you want to have someone pushing pressure on the wood as you're screwing in
once this was complete i moved over to the left hand side i've already got some lights
installed in the van so i wanted to cut some slits so that the lights can still be there
i could have disconnected the lights drilled some holes and reconnected them but i wanted to do a
bit quicker so i just cut some slits in the top of the wood that i could slide the wires down into
once i completed this side panel i then went to do the wheel boxes
i believe you screw the wheel boxes into the wheel arches but i was a bit unsure on this one so i
decided to use wood glue and just glue it down to the floor and the side plywood
bye
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