Robmac
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As some of you may know, I have just started to convert a 2012 Renault Master 2.3 DCI. It is a LWB version with an extra high top.
I have never attempted anything like this, so my mate Jim (Helmit of this forum) is helping me out, he completed his own conversion a while back.
Anyhoo, I thought I would record the conversion in a thread for those interested, and it will give me a pictorial record of the conversion, so here goes!
First of all, I stripped out the back of the van. It was lined with very thin ply which didn't cover the entire walls. I also removed the bulkhead between the drivers/passenger seats and the rear of the van. This gave us a blank canvas to work on;
I will not be adding a swivel seat, but the middle passenger seat will have it's rear squab removed to make a 'crawl through' access to the rear of the van in foul weather;
First job was to fit the floor. We used Stixall to glue 25x38mm battens to the metal floor;
Next, we overlaid the insulation. We used Premium Gold underfloor insulation from Harrison Trim Supplies;
We then laid 12mm WBP plywood and scred to the battens. I varnished all of the edges of the ply for further protection;
Today, we decided we would fit the windows. Quite scary when you have to cut holes in your van. I used 2 500x350mm windows for the washroom and sleeping end of the bed, and 2 700x500mm for the lounge area. These were all Seitz windows.
After a lot of careful measuring we cut the first hole. First we used a 25mm holesaw to cut the round corners;
Then, using a jigsaw the edges were cut;
Jim reckons my line was wonky. Personally, I think it's Jim's eyes being wonky as a result of many years of self abuse. But I wouldn't comment on that.
(OK it was a bit wonky, but soon sorted out with a file!)
Heeeeeere's Jimmy!
Several clamps were used to Stixall 18mm battens as an internal frame for the windows. These were space out with 6mm scrap ply for now. The windows have not been glued or sealed, and probably won't need to be (Thank you Mr Brown!). We will be removing them all to cut the ply lining apertures through the window holes (Thank you Mr Brown!);
And the finished job;
I will update the thread as we progress!
I have never attempted anything like this, so my mate Jim (Helmit of this forum) is helping me out, he completed his own conversion a while back.
Anyhoo, I thought I would record the conversion in a thread for those interested, and it will give me a pictorial record of the conversion, so here goes!
First of all, I stripped out the back of the van. It was lined with very thin ply which didn't cover the entire walls. I also removed the bulkhead between the drivers/passenger seats and the rear of the van. This gave us a blank canvas to work on;
I will not be adding a swivel seat, but the middle passenger seat will have it's rear squab removed to make a 'crawl through' access to the rear of the van in foul weather;
First job was to fit the floor. We used Stixall to glue 25x38mm battens to the metal floor;
Next, we overlaid the insulation. We used Premium Gold underfloor insulation from Harrison Trim Supplies;
We then laid 12mm WBP plywood and scred to the battens. I varnished all of the edges of the ply for further protection;
Today, we decided we would fit the windows. Quite scary when you have to cut holes in your van. I used 2 500x350mm windows for the washroom and sleeping end of the bed, and 2 700x500mm for the lounge area. These were all Seitz windows.
After a lot of careful measuring we cut the first hole. First we used a 25mm holesaw to cut the round corners;
Then, using a jigsaw the edges were cut;
Jim reckons my line was wonky. Personally, I think it's Jim's eyes being wonky as a result of many years of self abuse. But I wouldn't comment on that.
(OK it was a bit wonky, but soon sorted out with a file!)
Heeeeeere's Jimmy!
Several clamps were used to Stixall 18mm battens as an internal frame for the windows. These were space out with 6mm scrap ply for now. The windows have not been glued or sealed, and probably won't need to be (Thank you Mr Brown!). We will be removing them all to cut the ply lining apertures through the window holes (Thank you Mr Brown!);
And the finished job;
I will update the thread as we progress!
