Van certification quick fixes v3. All done.

Misc unsorted pics. Sunroof shroud finished and installed. (I didn't like the plastic one that came with it.) I got the certification sticker and paperwork already. Officially a motorhome. Test build prototype done. Will sell it when the time is right.

Grandmaster Gizmology Lesson 1

Something broken is merely parts for another job.

A broken spring clamp has valuable parts. Always fully disassemble before throwing anything away.

Springs go in the springs container. They will come in handy for some gizmo either tomorrow, or in 5yrs time...

Tiny bolts go in the M3/M4 bolts container. These will come in handy more often than the springs. Notice my supply is low.

You're technically not on the counter if one's feet and counter are separated by a box.

Spare cats go in boxes...

Van certification quick fixes v2

The weather cycle is rain, sun, rain, sun and cold each day at the moment. I had to perform a speed-operation and get the external work done for this tiny sunroof/vent.

I'm installing a small 300x300mm sunroof. It's really chintzy...So is melamine...so why pay $150k for a van furnished with melamine...

I had to 1/2 gut the van to get roof access and run some wiring for this tiny fan. I've installed a huge baggie up against the roof to catch debris as I cut a new hole for the sunroof.

Clean up for marking out and silicon application later.

I need a hole this big.

About there will do.

I'm gonna try out my $40 pneumatic nibbler. Will it blend?

Air tools are tethered...I need a longer air hose.

...let's get that a little closer to the roof, for what it's worth...

Oh noez it won't start cycling. Dunno why. Suspected stuck at the end of stroke. I gave up and literally hit it with a hammer. It finally cycled up.

Nibbler needs a 14mm (9/16th's) entry hole. Blech, that's way more than a jigsaw needs... :( I'm not excited by the cut that looks like an Oxy' torch cut either, or the barbed-wire moon crescent swarf. I gave up as my compressor doesn't maintain 90psi with this tool. This will go on the shelf and never get used again.

Modern JigSaws have a lateral reciprocation per-stroke that's a game changer. Absolutely ripped through the roof in no time.

I have to deal with some locator tabs that need additional space.

Glad I installed the catchment baggie against the ceiling.

Sheet metal work always has a component of red. I dunno why, it just does.

I deburred all the holes as I really don't like pop-rivet jobs that sit proud on top of flared out pilot holes. The cut hole and mount holes also got a hit with some spray paint.

Two beads of silicone.

Seems flush. ps: the hinge is at the leading edge.

The flapper disc didn't like the wobbly sheet metal at one point during clean up. Regardless; You never go back to grinding discs after you've used flapper discs. No comparison.

LOTS of woodwork to follow. The external work is done.

Van Certification quick fixes v1

As well as the stove issue mentioned in a previous post, I knew I might be on the borderline for certification on a few other issues. I finally got clarrification on these items during inspection. Once those are done I can send through photos of the updates and I will get my vehicle compliance sticker in the mail, and VicRoads documention via email. Then I'll finally have this thing registered as a "Motorised Caravan" as it's called in Victoria (for campers less than 4.5Tonne).

The outstanding items were latches on the cupboards, additional ventilation, and I needed to shoot down to the local public weigh bridge and get a ticket from them. Compliance is happy for a single whirly-gig in the roof, but I've ordered a cheap tiny sunroof with extractor fan as the price for both was similar. :( I desperately wanted to make some wooden latches for the cupboards but I need to wrap this up and there was a layer of customisation needed for regular bar-latches anyhow.

I grabbed a new portable 2 burner camp stove to sell with the van. It's no frills and is NOT a sales-pitch-item. It includes a grill element and non-battery peizo igniters which is pretty cool. Unfortunately it has no mount for the grill plate, and no place to mount the gas hose. Such a step backwards from our 40yr old camp stove that has both.

A bunch of brass latches should make short work of these cupboard issues.

I'm always reluctant to buy into cordless brands as the batteries will ultimately ALWAYS fail and you have to move on, but vehicle maintenance lighting has been a bug-bear of mine for a while, so I grabbed this cheap lil' LED lamp skin for my cordless batteries. It's a beast. Perfect.

I will need to do some custom work to make these brass latches work in the van as it was not designed with them in mind. You'll work it out as you browse the images.

Counter sunk screws into holes that arent appropriately counter sunk look stupid...Good job cheap products...

I ended up needing to modify every latch, and every catch to suit. The never ending burden of being a Master of Gizmology.

I needed to make riser-blocks for the latches on each of the nested sliding doors. It's very ugly...but the tank is running dry and this needs to be wrapped up. At least it's brass instead of nickel. Looks good on the timber.