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Anon
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Front unit carcase
A couple more days of dodging downpours but the carcase for the front unit is done -
Some bits look bowed but that's the camera: everything is straight & square.
From the side -
Some pencil chewing & head scratching to be done yet: plan is to install drawers & shelves to fit what's going to live in this unit.
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 Wed 14 Sep 2011 @ 21:12
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Anon
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Hello Phil,
Great job you're doing mate. Just one small question, where are you going to fit the bed? 
Rae & Ann
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Mon 19 Sep 2011 @ 23:34
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Anon
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Bed is a sleeping bag across the seats in the cab for the times when a quiet lay-by is a more sensible option than carrying on driving...
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Tue 20 Sep 2011 @ 12:30
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Anon
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Front unit drawers, left side
More rain dodging {sigh} & a bit of back-tracking before everything dropped into place with the first 3 drawers -
The top, middle & bottom drawers are all different in the the way that they fit the opening & order of assembly but now I've got a pattern hopefully the drawers for the right hand side won't take so much toil.
Main issue was in using deep section ball bearing runners -
The runners are overkill in terms of weight capacity but I like a good margin for wear & tear 
They need a degree of precision in installing them though ... measure umpteen times before drilling for mounting screws.
Bits of 4mm steel rod keep the drawers shut for travelling & ride along the tops of the sides of a drawer when it's opened -
More accuracy required in setting the rods in the sides of the opening so that the rods drop down of their own accord as the drawers close & then can be flipped up as the drawers are opened.
Jig made now for positioning the holes in the sides of the opening; jig also turned out just the thing for setting the bends in the rod.
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Tue 20 Sep 2011 @ 20:39
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Anon
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You know what Phil, hate blokes like you 
Looks a great job. Look forward to seeing the finished article.
Rae & Ann
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Tue 20 Sep 2011 @ 21:03
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raewaters wrote:
Look forward to seeing the finished article.
Em. There's 2 more units to build down the sides yet...
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Tue 20 Sep 2011 @ 21:45
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Anon
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Plan B
Started on the right hand drawers with the bottom one and was about to make a locking rod for it when it occurred to me that the locking rods will work just as well behind the drawer fronts and make things look a bit tidier.
So, scrap the existing 3 drawer fronts, move locking rods, modify the drawer sides to suit the rods then make new fronts & also a door for the centre cupboard -
This is first fix, everything working (except the right hand drawer that now needs a different front). There's an amount of fettling to do to even out the gaps but I've run out of time with slave job shifts looming.
Well worth the extra day for a much tidier look though & a spin-off is that setting the lock rods before the drawer fronts are fitted is a lot easier than previously.
Centre cupboard door is held closed by magnetic catches, a bit of an experiment: if the door will stay shut when travelling then they can stay; otherwise I'll have to engineer a latch of some sort behind the finger hole.
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Fri 23 Sep 2011 @ 20:19
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Anon
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one word phil, awsome 
love it looks hard wearing and in the home made industrial style 
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Mon 26 Sep 2011 @ 13:42
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Anon
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Right thats it.. I'm now boycotting this thread due to the sheer level of practicality & craftmanship being exhibited !
Just off to fix that wonky shelf. 
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Mon 26 Sep 2011 @ 13:57
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Anon
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;D And this all started off due to a bit of a scratch on his bumper
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Mon 26 Sep 2011 @ 19:41
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Anon
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What a transformation Phil you will be able to find things easyer good job.
Dave;]
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Tue 27 Sep 2011 @ 09:12
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Anon
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Thanks everyone for the appreciative comments.;]
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Tue 27 Sep 2011 @ 23:02
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Anon
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Front unit drawers, right side
After shuffling through offcuts (euphemism for mistakes...) with being determined not to start cutting into a new sheet of ply the last of the drawers got done -
Started the finishing by sizing the front of the middle, right drawer for a 2mm gap all round but then the belt sander upped and died; poor thing finally wore through its sole plate that then came adrift & wrapped itself around the drive roller (well, it's done a lot of miles of over some 12 years of use).
Even without the drawers finished I'm well pleased with achieving a flat front with minimal protrusions (the door hinges) -
Wasn't so pleased about spending money on a new sander even though the one that fitted me the best for smaller work turned out to be the cheapest own brand from B&Q.
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Tue 27 Sep 2011 @ 23:23
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Anon
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Left side unit, frame part done
The result of 2 days non-stop, of shaping ply to fit the side load door frame and body side while keeping the uprights parallel, square with the base and in line with the rear door frame edge -
Base frame is tied to the body at the side load and rear door frames. Uprights eventually will be tied at the top to the cant rail & the front upright will have another tie about the level of the sash cramp holding things together to check alignments.
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Thu 29 Sep 2011 @ 22:15
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Anon
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Left side unit, frame completed
More shaping of bits of ply to fit the curves on the van {sigh} and a re-think of how to tie in the top to the van body using the top shelf but once everything was screwed together it all went solid -
Front edge of the rear upright has drifted out of true by about 2mm at the top but that's only because the top piece is still a bit tight on the back edge; it would have got done today but there was a dead Renault Master to go fix, hence the bit of 2x1 screwed down across the floor to keep toolboxes from sliding forwards (although I needn't have bothered - thing had run out of diesel, is all).
Once the frame is fettled & glued together (it's mostly dry jointed still) there's some drawers to make & fit & decisions to make about what else is going to live in this unit according to weight distribution once the leisure battery is installed at floor level at the back. More head scratching...
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Fri 30 Sep 2011 @ 19:39
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Anon
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Left side unit drawers
Another week of making & fitting drawers -
It's not the making or even the first assembly into the unit that takes the time but making the fronts fit just so, involving much messing with alignments on the runners & locking bar positions so that all the drawers sit right when closed.
An example of dividers that are being knocked up in various arrangements -
Dividers are just pinned in for now so that they can be changed as things find their way to where they're best kept according to how much they're used & then the dividers can be glued in. Hopefully this will be before the bare wood gets so grubby that it'll need lots of cleaning up before being painted (like the bottom drawer front salvaged from an earlier version).
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Sat 08 Oct 2011 @ 19:36
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Anon
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The way its going Phil you will have enough room for a bed 
Dave
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Sun 09 Oct 2011 @ 08:34
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Anon
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Wow phil what a fantastic job and very informative too can your next project be a CF1
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Sun 09 Oct 2011 @ 13:28
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Anon
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DAVE ADVANTURA wrote:
The way its going Phil you will have enough room for a bed
Well, I should end up with a lot of floor space & even a camp bed would be better than across the cab seats but first I need to find a spare wheel carrier - van came without one. Spare is strapped against the right hand side on top of the wheel house for now but once the right hand unit is under way it'll have to live on the floor with the jack & stands. I'll have to fit interior handles to the doors too if I'm going to sleep in the back but that's not too hard.
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Sun 09 Oct 2011 @ 15:27
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Side pin wiper arms at last
After nearly losing both wiper blades because the Araldite holding the plastic 7mm fittings on had gone soft the arms had a fresh Araldite fix using new fittings -
Mentioned this to Skoota while giving him a hand with his Carlton (nice motor incidentally), to be presented with some side pin arms to play with.
Side pin arms had push-on spindle ends & the crank angle at the side pin end was more shallow than the CF arms but the length was right for converting the CF arms to side pin -
First unhook the spring then drill out the rivet holding the arm together -
Then open up the clinched over edges -
After which the arm comes apart with a tug & a twist.
Transfer side pin bit to CF bit, replace rivet with M4 bolt & nut then clinch over to make the join tight.
Clamp side pin end in vice, bash to right shape then install -
One happy bunny, much thanks to Skoota.
EDIT
After a trip out to Burnley in the rain even more pleased: side pin wipers a lot quieter & no judder as the screen dries out. Just need to remember to repaint them at some point...
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Wed 19 Oct 2011 @ 22:10
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