Micro Mods: Window Winder Wheels

The cab area will be one of the last parts of the van to have any sort of modification done to it. Other than the footwell lights and the cab light it is pretty much untouched.

Then I saw this mod done on the T5 forum and thought I'd give it a go. At first glance I couldn't work out how the winder handles came off, but it's dead easy once you know...

Simply squeeze the lock-ring behind the handle and pull it in the opposite direction to that which the handle is pointing - simple. Then it just pulls away from the mechanism.

Once off I simply chopped the back of the small wheel section to remove the spinning part. Then using a small cabinet connecting bolt and some loctite on the thread, add the skateboard wheel of your choice:

Before and after

Then just replace the handle in the opposite of removal. It's probably wise when choosing your skateboard wheel to keep the diameter small, a larger wheel might put too much stress on the handle - Stone174 accepts no responsibility for your own breakages!

And here's the finished thing, for now. The beauty of this mod is being able to change the wheels for something else at a later date:

  

Multirail - UK Instructions

I've had a few people comment on the fitting of the Reimo Multirail.

In particular those that are struggling with the 'german-only' instructions. I spent a bit of time translating (as best as possible) then copying and pasting over the original instructions. See below:

Click the pic for a bigger version

The translation is by no means perfect, but should be enough to get you through.

If you're new to the Stone174 blog you can see the previous posts featuring the multirail by clicking here.

Multirail (part three)

So here's the Multirail in use...


To attach to the awning; position the van, slide on the double-edged beading strip, then holding the awning bead and beaded strip, feed the figure of eight strip between the two.

To detach the awning simply pull the double-edged beading strip out of the Multirail end and you're done.

No unsightly ropes slung over the van, quick and easy. If you've got a T5 and want a drive-away awning this option, although more expensive, is well worth it!

Multirail (part one)

Vehicle design is a wonderful thing. Every generation of a certain model becomes increasingly more refined, lines get smoothed, tidied and updated. Unfortunately trends change - in the case of the Volkswagen Transporter, the gutters have disappeared. They left us after the third generation van.


Our old T3 camper was often extended with a canopy or drive-away awning hanging from the gutter, something we're keen to retain on the new van, but how?

We had a long chat with Mark from Fishbrain; the company we have just bought the Khyam awning from, his recommendation was a Reimo Multirail:


A myriad of awning and canopy attachments are possible using the standard 'figure of eight' strip as used by most awning manufacturers. This seemed the most sensible (but not cheapest) option to go for. Other options include ropes going over the top of the van's paintwork. Simply not an option for us.

So off we go. First step is to mask the length of the van and offer the Multirail up and mark the drill holes. Check, check and check again.


Notice any small gaps above and below windows have been covered with masking tape, this stops the small shards of metal from drilling getting anywhere near the rubbers.


Don't be put-off by the Multirail being 'dead-straight', it will curve to the contour of the van when screwed and bonded into place.


Deep breath... and drill! There's no going back at this stage. Roughen the paintwork between the holes to help the bonding process.


Add the bonding (sikaflex style bonding material) to the Multirail. Clean the van surface with an acetone-based 'panel-wipe' and offer-up the Multirail.

Starting at the front, first two screws in, then work your way down the length of the van.

Just as we got to this point the heavens opened. Rain-stopped play - hence the part one in the title of this post!

Check back soon (if the rain ever stops!) to see the final result.

UPDATE: Here's all the other blog posts about the Multirail.

Spending a weekend on your knees...

Time to get the floor sorted.

We camped in the van last weekend for the first time at Bustypes, the April evenings were still pretty chilly. Having insulated the roof and walls, the only really cold spot left was the floor. Determined not to repeat the cold night's sleep for next weekend's Stanford Hall show, it's time the floor was put right.

First up is even more sound deadening. Just in select areas to add weight to the vibrating panels.


Next up, insulation, again to begin with, in the larger gaps between the floor's corrugations.


Then on to full lengths of insulation for the whole floor:


Building up those layers. Next it's a layer of laminate floor underlay:


After this, the new plywood goes down. This was cut using the old rough ply as a template, tidying up any edges where necessary.



Finally, the rubber tiles go down as the final layer.


The tiles were bought cheap from B&Q as a discontinued line and, as such, we're not able to buy in batches of continued part numbers. The downside of this is some of the tiles, although black, appear blue in strong sunlight. As this is only a temporary floor until the main camping interior goes in, we're not too concerned. By the time we've given the floor some abuse it won't matter that the tiles don't match exactly!

Here's an example of the kind of 'weekend load' the van gets to carry:


One final tip: As it's hard to source a single piece of ply big enough for the floor of your van, it's good to mark out a centre-line. It's a great way of keeping things square as the floor of the T5 tapers slightly narrower towards the front. Cutting and measuring materials this weekend would have been twice as hard without it!



Next weekend: a trip to the Stanford Hall show in Leicestershire. Picking up our new Khyam Drive-away awning too - a report will follow shortly after.

Even more sound proofing...

If you've ever slept in a van-based campervan you'll understand how the sound of gentle rainfall pitter-pattering on the roof of the van can lull you into a beautiful night's sleep...

You'll also know that anything more than the lightest of showers is more akin to someone throwing handfuls of gravel directly at you. Unsurprisingly this doesn't make for a great evening's slumber.

Keen to 'deaden' some of this external sound I'm adding some weight to the roof panel using the same method as the side panels; self-adhesive flashing tape. It's a proven method as shown in the image below, Volkswagen stick this stuff in at the factory, albeit they're rather economical with the amount used!


So with the roof lining off I've started to add more:


And, as usual, I've run out! I'll give you an update of the end-result later this week.

On a final note, here's my 'tool-of-the-day':


The interior panel clips that Volkswagen use in assembly are great, for one-time assembly only. The where never designed to come out again. That's where this little tool comes into it's own. It allows you to slowly prize away at clips and 'blind' interior fixings offering just enough leverage to get things moving. Many hours of cursing and breaking clips has been saved by this tool.

Insulation part two

Time to get some Celotex into the rear cavities.


First up (as mentioned in a previous post) is some panel-weighting.


This is fitted to take out some of the resonance (road noise) made by a vibrating panel. There's big chunks of it on the wheel arch down inside the cavity.

Next up, the Celotex goes in...


Due to the small apertures this has to go in in relatively small pieces. There's not much scope here for a good-looking job, just an effective one!

Next in, thermo-wrap


Cut to size and slide it in. There will also be thermo wrap taped to the back of the panel that covers back over.

The final stage is a sheet of polythene to cover the apertures, sealed with waterproof tape.

And that's it...

The standard grey Volkswagen panel clips back on as before. For a whole afternoon's work it doesn't really look like I've done anything, does it?

Interior Panel Covering

With the ongoing insulation project, the interior plywood panels are out of the van and in the garage - a perfect opportunity to get on with the task of covering them with automotive lining carpet.

Unlike ordinary carpet, this lining carpet is woven on an elasticated mesh which allows a certain amount of stretching and contraction around the various complex shapes found in vehicle interiors. The carpet also has very little 'backing' and so takes to glueing quite easily. Which is good because I hate using glue!

If I could give out only one tip for this procedure it would be 'take your time'. It's not a job to be rushed, however much you can't wait to see the end result.

So, off we go...


First a bit of prep. A quick sanding of the edges will save any splinter-based fun later. A light sanding across the whole panel will also help the glueing process. Don't forget to check your lefts and rights - the last thing you want to do is carpet the wrong side of a panel!

On to the sticky stuff...


Not much to say really, just follow the directions on the tub. Don't forget a bit of ventilation - there's nothing like a glue-buzz to leave you sticking things at crazy angles!

Like buttering toast...


...on a grand scale. Again, take your time, this glue works best after 30 minutes or so, so there's no need to rush.

Carpet on and flip.


Cut your carpet pretty generous, there's no point being stingy. Lay the carpet onto the glued panel and smooth out. Then flip the panel over and start trimming up the edges. This is also the point to make any nips and tucks to get the carpet to follow any curved contours of the panel edge.
Then it's a quick once around the panel edges with the glue in preparation for folding the carpet over the edges.

It's a wrap...


Clean hands time. Carefully fold the carpet around the edges and corners of the panel and you're done. A few weights can come in handy at this point whilst the glue goes off.

Here's a quick before and after of the big panel over the rear wheel arch.





I'll post a finished panel picture next week just before refit.

Time-wise; two sliding door panels and two large rear panels have taken the best part of a day to do - although much of this is waiting for glue to go off, washing hands of glue, drinking coffee and coming-down from glue-highs!