Almost done?

I've now nearly finished the soundproofed (the same soundproof underlay I've used for the sides of the van) wheel arch storage boxes. Here's the driver's side one, carpeted, soundproofed and hinged lid fitted. Just need to fix them into the van now.

More progress + Electrickery

Some brief dry spells this week allowed me to get a bit more carpeting done. The final two side panels are now completed - with batons for the wheel arch boxes to screw into and MDF reinforcing rings where the speakers are to be mounted. I'm really pleased with the result - it's starting to look pretty smart (although I'd quite like it to be all finished now!)


























More rain was forecast this weekend so I decided to have a go at the electrics as this could be done inside the van in the dry. I removed the head-lining and roof panels to reveal the spider's web of wiring left over from the van's AA days (when it used to have flashing beacons etc on the roof)










Spent a few hours with a multimeter working out what did what, what could be removed, what should stay etc. I re-wired the original interior lights so they worked off the side and rear doors then re-wired the 8W florescent tube lights so they could be used regardless of whether the doors were open or closed. While the head-lining and roof was down I ran new speaker cables from the head unit in the dash, up the front windscreen pillar and along the roof to the holes where the rear speakers are going to be fitted. I also fitted the new Blaupunkt AM/FM aerial I'd bought from Germany off eBay which mounts to the inside of the windscreen glass (the original VW aerial is broken and replacing it involves removing the front wing, glove box and wheel arch) The new one looks a bit strange with little wires along the top and down the side of the windscreen but I'm sure I'll get used to that, plus the reception seems pretty good (it has a built in signal amplifier).

In the end it stayed dry today so I also managed to also carpet the two roof panels and re-fit them - so that's all the carpeting done except the wheel arch boxes (this coming week's job!)

After a full day on my knees and bent over double in the back of the van it's time for bed...

Carpet

So far I have managed to carpet the 3 door panels and the floor. I'm getting better at cutting and folding the carpet over the edges of the panels to get a neat finish - it's especially difficult round the corners. I found that the easiest way of making holes for the carpet for the panel fixings is to use an old soldering iron (being careful not to breath in the fumes) I've done the same on the floor where I've made holes where some of the tie-down threaded holes are. By melting the hole with the soldering iron, you get a neat edge with minimum risk of fraying. I've bought some lower profile M10 roofing bolts to replace the large socket head ones that used to hold the floor down.













I've also re-fitted the aluminium edging strips along the rear edge and around the side step to protect the edges of the carpet. So, just the side panels and headlining to do now. I've cut the speaker holes and MDF reinforcement and spacer rings for the rear side panels, so need to fix these and the battens for the wheel arch boxes to screw into and then these will be ready for carpeting too.

Floor

Carpet arrives tomorrow so I finished off the rest of the sound proofing today, including taking up the floor, cleaning underneath then putting the sound proof underlay down under the ply.

I'm getting there!

Plywood and more Sound Proofing

Stripped out the remainder of the wall panels and used the old panels as templates to cut out new ones out of 4mm thick plywood. Still waiting for the carpet to arrive so just a quick check to make sure everything's going to fit then continuing with the roof flashing sound deadening (also using Dynamat Xtreme behind where the rear speakers are going to be situated) and the sound proof underlay over all that.

Wheel Arch Boxes

Also making the wheel arch boxes at the moment which are not only going to hopefully reduce road noise in the back (once the trusty sound-deadening and sound proof underlay is in place) but also provide useful storage compartments for things like jump leads, jack, tools etc.

Here's the first sections being glued (having to work in-between rain showers which is really frustrating)










Have had to cut some pretty interesting shapes to fit round the seatbelt anchor points, and I've now found that the back of the van is no-where near square so everthing has had to be cut at funny angles to fit. But I reckon once they're covered in carpet they're going to look pretty nice :)

Soundproofing

I've started work in the back of the van now. First job was to take the panels off and apply sound-deadening (mixture of Dynamat Xtreme and roof flashing) to the metal panels to stop them ringing.















I then bought 10 sq metres of sound absorbing laminate floor underlay which claims a 23dB reduction in sound so this is also going in before the panels are put back in place.












The final step will be to trace round the old plastic panels onto ply wood and cut out new ones. I ordered a load of light grey carpet to cover the new ply wood panels in before they are fixed back in place. There should be enough carpet to also cover the headlining and floor so should look pretty smart once finished but I'm starting to realise what a massive job I've undertaken!