This is a big one. These tasks were all completed in parallel to each other. I'm going to try and group things together in some coherent order, but the images will not always be presented in chronological order.
The Bedroom
A prerequisite of creating the bedroom is to panel up the garage. For this I used the existing ply lining that came with the van.
To support the bed there are two lengths of aluminium angle, 50x50x5mm thick, on each side of the van which are bolted to the main beam using rivnuts. I used existing bolts and washers that came with the van, as they were fairly heavy duty. I also made use of the tie-down hoops. The frame is supported on these using some aluminium profile.
I made use of the channels in the profile and 3D printed some T nuts to screw the ply in to.
Next the mattress needed to be made to fit, which means chopping the corners off to make room for the rear pillars.
After some testing much later I found I didn't need the bed so high, so I lowered it.
Garage
So there's two walls already in, the main bit left is to sort out the wheel arches. For this I insulated them with closed cell foam and boxed them in.
I added a mains socket mostly because I could. I figured that it might be useful to charge an e-bike or power tools and such from the garage of the van.
Ceiling
First bit of ceiling to tackle is the cap forehead. If you recall from part 8 I had to cut around the aerial for the insulation. This time I had to accommodate the aerial wire, which was going to be in the inside of the ceiling. Since the panel for this was going to be held in between the insulation and structural beam I cut a slot out for the cable.
The first board, over the cab, was screwed directly to the van beam, but the rest will be screwed in to battens which are attached to the ceiling.
I had to figure out where the lights would be. This means having the first batten in 3 parts. I held up the roof lights blinds to get an idea of where that would be
One of the challenges is around the passenger B pillar coming in to the van, so I had to scribe around that.
I also had to measure and cut out the hole for the roof light as I don't have a router to do a flush trim with.
The remaining roof battens were a bit more straight forward
Now, I failed to document the next few bits, but basically all that's happened is I've used some PVC H trim to join the panels and screwed them in to the battens, with the occasional hole for a light.
Lights
I'm going down a totally DIY route for lights. This means I've soldered 1W LEDs to PCBs which are then driven away from the light fixture itself, and placed them in to a 3D printed housing. This will allow me to have a very fine control over the LEDs and also make any changes, like colour temperature, super cheap and easy.
Walls
All but two walls are done with 6mm ply.
Both the shower and kitchen walls will be clad in another material later.
The lower seating wall is done in 12mm ply as it will be used to mount various electronics, such as the solar charge controller and inverter.
The upper wall is done with 3mm wall board that was used as a sacrificial surface for transporting my 15mm furniture board. It was in good enough condition to be used for this and is a bit more interesting than plain ply. I may also clad this with another surface later on (thinking something padded to reduce echo).
