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Van Build Part 10 Stage 3 Insulation

Have the solar mounted, Maxair fitted, wall panels sanded and undercoated first 80 grit then 120 then 240 grit in-between coats . The same with the hardwood ply panels. Start the top coat tomorrow and dry fitting to cut the holes for the wiring. Have also started fitting the insulation to the back of the timber panels. Much easier than connecting to the steel and if the panels ever require removing everything peals away with one section.

maxair fitted
undercoated and sanded ready for top coat
insulation backing attached

Van Build Part 8 Wiring

Today was fitting the solar panels, puttying the walls ready to paint, threading wiring through the walls and varnishing the hard wood panels. Had change of mind with the color arrangement. Instead of the black on timber look, may go for a hardwood varnished look on a beige wall concept. Had never realized there were so-many types of ply wood since visiting Tasmania.

feeding wiring though cavity’s
puttying the walls to paint
hard wood stencils finished
solar panels mounted
varnished the hardwood

Been a long day. Shoulder played up after feeding wire all day. Between the two of us almost half a bottle of whiskey gone. Been over doing it. Not all fun and games building a van. Between the back injuries, leg injuries, reduced lung capacity. I’m feeling it but after 12 years on an oxygen bottle and four years in a wheel chair, loving every minute of it though. Good catching up with a mate too. If I’m not doing something I feel disabled, at-least working I feel like I’m accomplishing something F*k the pain.

Van Build Part 7 More Stenciling And Solar Brackets

Today was more stenciling for the rear door and manufacturing brackets for attaching the solar panels onto the roof racks. Will require a four man job to lift them onto the van. Time to start feeding the internal wiring network.

one last panel to stencil before cutting hardwood
my mate finally finished the cooking knife
bracket manufacturing
first frost of the year
would have been the best picture of the day but miss timed the windscreen wipers

Van Build Part 6 Stencils

The job for the past two days are making stencils to replace the two rear door cover plates. Before making the door covers out of hard wood ply and painting.

from plastic covers
to full sheet cover panels out of MDF for patterns to below
to smaller inlay covers to look neater
stenciling process before tracing corners out
finding the curves

The smaller covers will fit better, but will have to have other blocks made for the door mechanisms. Going to head off shortly and watch my mates wife sing in a band at the local pub (Blue Chili). Haven’t had a beer in a long while, looking forward to a schnitzel parmigiana before finishing off the roof racks and door panels cut outs.

The hot spiced cider around the burn barrels got the best of me, knock off time for work today. Spending the rest of the afternoon keeping my mate company in the workshop while he finishes off a Myrtle Burl knife handle sipping whiskey by the fire.

shaped ready to polish

Van Build Part 5 Flooring

Today we got stuck into the van. My mate has almost caught up on his projects. He just has to finish a handle on a custom blade he’s been working on. Laminated with Damascus copper with a burl epoxy handle. Managed stage 3 insulation under the floor, laid the floor. Still have to trim the front door edge. Started the stage 3 insulation on the doors and have almost finished mounting the roof racks to hold the solar panels.

Damascus laminated with copper hand forged
stage 3 insulation cutting for floor
under floor insulation
floor laid ready to be trimmed by doorway
stenciling door panels
roof racks partially mounted ready for additional attachment points

Van Build Part 4 Second Stage Insulation

Started the second stage insulation today. 10mm foam with backing. Sticks much easier than the stuff that was sold years ago. Great products from Car Builders. Will probably have 24 sheets of sound deadener left and a full box of 10mm foam.

The view from the Antarctic cafe for breakfast

Not a bad effort for a guy with a f*ked knee, two fu*&d shoulders and a Fu&ed back. However Im back on the heavy meds at the end of the day.

Van Build Part 3 Stage 1 Insulation

Stage 1 insulation, the sound deadener. Been keeping myself busy plodding along with filling in the deadener while waiting on my mate to finish up on his projects. Have started cutting stage 2 insulation the foam to fit over the top.

The above is why I drove all the way to Tasmania to have a boat builder work on my van furniture. At the moment were thinking of using Celery Top timber for the bench-top due to stability and weight and using a live edge with a laminated sassafras top for the grain structure. The above is Huon Pine epoxy pour matt black epoxy finish part of an upcoming exhibition, where the ancient meets the modern. Huon Pine only grows in Tasmania and was traditionally used in boat building. (Lagarostrobos franklinii).

Esse Junglas Mods Part 3

Too wet today to work on my van, decided to do some knife work instead and stripped the Esse Junglas, ready to patina.

handle off ready to paint strip
after paint removed and scrapped
still left a grey finish that required a scotch brite wheel belt to remove
showing the difference between the finishes
scotch brite belt
fully stripped ready to dip
ferric acid bath first followed by coffee dip
finished piece sitting on an unfinished Huon Pine coffee table. May give it another dip as yet but its a user.

Setting Up New Rapid Ridge-line System

Trying out Dave Canterbury’s new ridge-line system using toggles.

toggles 100mm long
carving and debarking the tea tree wood
setting up the prusic loops to tension the tarp
using a figure 8 instead of a bowline
almost forgot the last loop for the anchor point
takes seconds to deploy
holds tension very well

Rapid Ridge-line System ? It works really well but it did take me 2 hours to put together. With finding the cordage, trying a figure 8 loop, double stopper knots, prusic knots, larkshead knots and double fisherman’s knots. Carving, cutting and drilling the tea tree. Id still like to adjust the prusic loops to be shorter to prevent tangling. Ive also used a figure 8 instead of the standard bowline, it doesn’t come undone with the 750 cord that I use for oilskin tarps over the 550 cord. Ive also used 4 prusic loops with toggles, 2 for the ends and 2 for the center loops of the tarp.

EDIT 25th May

Have redone the loops using 3mm paracord instead of hootchie cord. Less tangles this way, I also don’t like using bank-line for the same reason. I started off with two lengths of 300mm I’m now using two lengths of 250mm or 500mm in total lengths. I see many people using the same diameter cordage for the ridge-line as for the prusics, this doesn’t work.

loop size comparison
finished showing half sized loops to previous version
3mm tactical 3 strand vs hootchie cord

3mm Tactical

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