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Ben's white 2.5 Build [pics]

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478K views 500 replies 206 participants last post by  Pickledog  
#1 · (Edited)
My Build thread!
Shes a 2000 2.5tdi, with intercooler, remap etc to around 128, K&N etc in super condition but ready for some attention. only 84k from new (as of Jan '11) already had webasto roof, alloys, side bars, decent stereo and parrot bluetooth, VW history.. lovely :)

Quick index:

Page 1 - Insulation - Barn doors, nearside rear panel, start of offside
Page 2 - Insulation- Offside panel, refit play, new floor
Page 3 - Carpet lining- Barn doors, nearside rear panel & arch box
Page 4 - Carpet lining - Stretchy on barn doors & internal mouldings
.............LED fittings and regulator assemblies
.............Insulation - roof area
.............Roof lining carpet and refit with new LED fittings
Page 5 - Start of Seating build with aluminium extrusions
.............Bumpers heat gun treatment
.............Seats/bed cladding and soundproof foam
Page 6 - Webasto sunroof re-cover
Page 7 - start building long side of L shaped seating
Page 8 - Remove K&N filter and fit standard airbox
.............Step covers arrive, replace rear badges, and digression onto motorbikes ;-)
Page 9 - Carpet lining - second barn door
.............Make leisure battery tray, mount RCDs etc
Page 10 - bed frame completed and memory foam cut to size
Page 11 - upgraded Headlight loom, and in-dash digital voltmeters
.............Side window installed in sliding door
Page 12 - first cushion made on new sewing machine
.............Eberspacher Installation
Page 14 - build of full height end storage unit
Page 16 - build rest of rear cabinets
............. cover A pillar with alcantera cloth
Page 17
..............Eibach Springs fitted
..............Van-X curtains fitted
..............VW front mudflaps fitted
..............Replacement sliding door mounts
..............12v sockets mounted and wired in
..............12v laptop charger
Page 18
..............Cab Headlining and A Pillars
Page 19
..............Ambient Lighting in footwells
..............Waeco CDF-25 Fridge freezer and mounting unit.
Page 20
..............Repainting door cards and trim
..............Carpetlining lower half of doors
Page 21
..............adding additional vent to cab for Eberspacher
Page 22
..............Top-of-dash display pod for satnav screens etc
..............USB power unit built into dash for satnav feed
..............Replace Parrot kit and Alpine head unit with Kenwood
Page 23
..............CB radio install, display and main unit, & box mike and controller etc
Page 27
..............LED door handle mod, roof box
Page 28
..............Major Dash mods, Passat Hazard switch, integrated satnav install
Page 29
..............Relocate CB display screen, paint new dash topper, mats
Page 30
..............Customise Roofbox
Page 31
..............Passenger 'sleep' cushion
Page 32
..............Cosmetic updates
Page 33
..............Dashcam installation, Fit Cruise control, hidden safe
Page 34
..............Extra 12v socket, Service & cambelt, Sachs HD shocks


This is as she arrived to me in January 2011:

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This is now the start of my build, with the first post being 11/1/11:

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I've just started to insulate my new van, ready for the next stages :)

Just done one rear door to get a feel for it so far.

Ply panel off, surface wiped etc:

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bubble insulation (with double-sided foil) shaped and lining the whole of the inner structure, stuck on with spray glue (Used a small wallpaper roller to smooth out as far as possible!)

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Celotex blocks cut to shape and fitted. (BARGAIN! Local Travis Perkins had a bunch of damaged panels, let me just have them..) Eco-plastic insulation wool packed in all the beams, gaps etc (other than round the mechanism, didnt want it jamming) and then Aluminium foil tape to seal.

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PLastic sheet to seal the whole thing, sealed with waterproof tape.

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Ply panel back in place. (Cloth/carpet lining will follow later!)

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I'm enjoying this :)

Ben
 
#2 · (Edited)
Re: Just started to insulate... [pics]

spot on thats how i did mine. youll find thermal wrap is good and sound deadning. i did mine 3 layers thick thou :eek:
in the awkward areas i used recycled plastic bottle insulation as well. which dosent soak up moisture like a sponge.

the added advantage of sound deadening with the thermal wrap has two benefits, warmth and very light wait which is what you need for an aerodynamic brick on rollerskates. :(

youll find van nice and warm and quite when driving! keep up the quality work T:

i also waxoyiled as well which will look after time spent and your investment! :D :ILU:
 
#3 ·
Re: Just started to insulate... [pics]

Ah ok, I've only done one layer of the bubble/foil stuff. The recycled bottle insulation though is exactly what I'm using, its in every possible nook and cranny there!

Thanks for the feedback, I was basing what I was doing on stuff I'd read before finding this site, but its always different when you start to do it yourself!

Cheers :)
 
#9 ·
Re: Just started to insulate... [pics]

Thanks all :)

I'm pleased with how its going, though its taking me longer than I expected - but I dont mind that, I'm quite enjoying it :)

The ECO recycled bottle insulation is from B&Q, in with their normal loft insulation, looks just the same only a bluey/green colour. That's it in the picture below...

It doesn't itch, at all! It doesnt hold moisture the same either apparently, and its absolutely fine to work with, (I hate the feel of normal loft insulation so this is a good thing!!)

It seems to go a long way too. I've spent ages with a long narrow screwdriver poking it into every little hole to fill up all the beams etc :)

I need to pause now - Knees hurt, running out of Aluminium foil tape, hands are black and fluffy from the combination of spray glue and fluffy insulation!!

Anyway - Sliding door now done! This was quite fiddly, I was very careful to avoid affecting the lock mechanisms with the insulation, so 'sealed' all that into its own space with the bubblewrap stuff before starting on the rest of it. There are some fiddly shapes in the door too. Not difficult, any of it, but definately fiddly.

So far Ive used - One full roll of B&Q double sided foil wrap stuff, thats literally just run out. Almost two rolls of Aluminium tape. 1 full roll of recycled insulation, thats the second one just opened in the picture. A quantity of cellotex, but not fussed about that, it was free! Still on first can of spray glue too.

I bought three rolls of the bubblewrap stuff - reckon that was spot on for walls and doors, but dont think it will be enough for floor/ceiling as well. I bought three cans of spray, may be too much. I bought three rolls of insulation - Thats probably fine. Will work out a definitive list when Ive finished, though I'm going to have to go and buy more cellotex, all the stuff I have left is about 10cm thick, and thats too much by a good margin!

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Thanks for the feedback, all :)


Ben
 
#10 ·
Re: Just started to insulate... [pics]

Today's progress somewhat disrupted due to visitors and family and having to buy and fit a new battery etc etc.. Anyway, update:

Removed the old racking. This took AGES - whoever put it together used about 400 screws, and the screwheads were all made of cheese, you only had to look at them and they melted, no grip at all. Fun!

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Racking out, then a bit of fun removing the ply lining from that side, and then we're ready to go:

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The time consuming bit is getting the recycled wool into every nook and cranny and hole to fill up and insulate all the beams and crossmembers etc. reckon it has to be worth it though!

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Getting through that aluminium foil tape too... :)

Fun times!

Next step: fill up all the hollows.. I'm tempted to continue but it's 11pm already!
 
#11 ·
Re: Just started to insulate... [pics]

OK, so I carried on, its now 1am!

Tried it slightly different on this side. Completely lined with thermal wrap as shown above, but I thought I would see how it was to just use the ECO recycled insulation wool, to fill everything up, and then put another layer of thermal wrap on top.

Have to say, it's loads easier to do this!

Pics:

Space:

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ECO insulation:

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Cover and foil tape:

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That went well, so I carried on doing it this way:

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Again, good times.
 
P
#12 ·
Re: Just started to insulate... [pics]

because u have the bubble foil, will u need to put in a vapor barrier? ive put roc wool in mine as it was getting thrown out and have plyd but have been told to put up a barrier before the ply. i was planning on taking the lot out and putting the bubble foil on the out side skin and then putting the roc wool back in. ive packed it in so that it wouldnt all fall down over time. vapor barrier needed then?
 
#14 ·
Re: Just started to insulate... [pics]

That's exactly what I've done here. A full lining of the bubble foil thermal stuff, then the wool (or a combination of Celotex and wool) then seal the lot with another layer of double-sided bubble foil, using aluminium foil tape to completely seal all the edges...
 
M
#477 ·
Re: Just started to insulate... [pics]

Bascule said:
That's exactly what I've done here. A full lining of the bubble foil thermal stuff, then the wool (or a combination of Celotex and wool) then seal the lot with another layer of double-sided bubble foil, using aluminium foil tape to completely seal all the edges...
Click to expand...
I've been looking at the various techniques for insulation proposed in the forum. A lot of people worry about it, probably too much. I like the foil wrap idea across edges and pillars with celotex on main panels. The foil insulation will allow you to cross many thermal bridges (cross members/pillars) and act as a vapour barrier.

I noticed someone asked about a vapour barrier. My understanding is that a vapour barrier Should only be on the inside of the main insulating layer if you are insulating for cold environments. This is because the moisture that condenses on the cold metalwork will come from warm air in the van. This will happen through unsealed holes and at exposed thermal bridges (eg windows and uninsulated metalwork.

Everything outside the vapour barrier (inside the metal skin of the van) should be as breathable and ventilated as possible. In reality, vans are flexing and well ventilated structures so as long as its driven regularly, airflow is inevitable and rust will be unlikely.

If packing a cavity like in this thread (I think this is futile anyways as the surrounding metal work will thermal bridge it), making sure the inside of the insulating layer is sealed for vapour as you have done is vital as you are restricting the ventilation that might clear any condensation forming there.

Sealing material between vapour layers, although it sounds like a 'belt and braces' method is not ideal either as again, any moisture that might get inbetween will find it very hard to escape. That said...it doesn't really matter if it's there, what's it really going to do?

I think the logic here is sound. Please let me know if I have not got the right idea somewhere here though.
 
#15 ·
Re: Just started to insulate... [pics]

Holy insulation overkill, thats awesome bud T:T:T: You will be snug in there all year round, make sure you have adequate ventilation when you are sleeping in it. T:T:T:
 
#16 ·
Re: Just started to insulate... [pics]

Do you think ventilation will be an issue? I hadn't given that a vast amount of thought tbh. I haven't covered up the two vents either Side behind the wheel arches..but they let air out rather than in, they have flaps against inbound airflow..

There's a draught under the rear doors at the moment, I assumed I would deal with that in due course..!

All input appreciated!
 
#17 ·
Re: Just started to insulate... [pics]

Its always an issue mate especially when heating the van in the winter and sleeping/cooking in it. Cheapest front ventilation is wind deflectors and perhaps a couple of decent sunroofs or proper low profile caravan roof vents. I have an awning to use this year so hopefully i will be able to leave the van door open all the time when we are with the van which will give better ventilation.
 
#19 ·
Re: Just started to insulate... [pics]

Todays progress.. not fully documented, went over to my mums to do all the flooring etc and didn't have the camera with me!

Anyway:

Finished off the drivers side, got all the ply panelling put back into place, did all the floor work.. Next step is the rooflining, but not going to have time to get to this for a little while!

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Panelling restore in progress, starting to do the space under the arch boxes etc

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Jump to the end of the day and a scrappy iPhone pic to show the new flooring in place!

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Took longer than I would have liked, but v pleased with progress for a quick weekend job..

Ben
 
Y
#369 ·
Re: Just started to insulate... [pics]

Bascule said:
Todays progress.. not fully documented, went over to my mums to do all the flooring etc and didn't have the camera with me!

Anyway:

Finished off the drivers side, got all the ply panelling put back into place, did all the floor work.. Next step is the rooflining, but not going to have time to get to this for a little while!

Image


Panelling restore in progress, starting to do the space under the arch boxes etc

Image


Jump to the end of the day and a scrappy iPhone pic to show the new flooring in place!

Image


Took longer than I would have liked, but v pleased with progress for a quick weekend job..

Ben
Click to expand...
Hi Ben, just looking for some advice. I have lifted the floor on my van, going to ali double foil the floor, but did you use any insuation under the floor as well or just foil?

Thanks
 
#20 ·
Re: Just started to insulate... [pics]

that is awesome pal, you're thread has helped me no end, this is going to be the first job to our van when we get it saturday!

Have you done the floor and roof?

Any special tools needed?

How many rolls or what have you used and where from mate?

Nice one pal. Cheers for taking the time
 
#21 ·
Re: Just started to insulate... [pics]

I've done the floor, (no pics) but haven't yet started the roof.

This weekend I have bought 7.5m of Grey Carpet lining to do all round the sides, and 2.5m of Black to do the roof lining.

I've also had almost no time to do anything with it! Small update to follow... I've also been fitting in a bit of T-Cut and polish work, to brighten it up, coming along nicely..

Tools - a good pair of scissors for the thermal wrap. Power screwdriver. some long thin screwdrivers for poking the Eco-wool into all the beams! Thats about it..

Whats been used.. well about 6 rollls of the Thermal wrap from B&Q at about £16 a pop. They do some single-sided stuff at about half that but I reckon the double-sided was worth the extra. Ive used 4 or 5 rolls of the ECO-recycled insulation wool too, at a similar price. I've used about 4 rolls of Aluminium foil tape, not cheap but hey. All from B&Q.

Hope that helps, shout if I can help any further!
 
#22 ·
Re: Just started to insulate... [pics]

Today's progress..

Some lengthy by-hand t-cut and polish. Did some earlier with the old Porter-cable, but the paint is basically first rate and only needs a minor re-awakening, by hand is proving fine :)

I also couldnt resist starting on the carpet lining and I also bought some Ikea Dioder LED lights and a bunch of low voltage cable but not yet started to fit any of that. I've also found some superb LED light strips and diffuser very cheap at Farnell - will post part number later.

Anyway, a few pics to show what I was doing earlier.. Back doors only.. Never done this before so any tips on making it an easier process would be appreciated!

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both panels now fitted and looking sweet, am itching to get the rest done. Grey sidewalls, black roof, should be cool..

Ben
 
#25 ·
Re: Just started to insulate... [pics]

angchris78 said:
What colour is this carpet.? I mean what colour do mega van mats call it.?
Click to expand...
This carpet wasn't from Megavanmats, this is the totally non-strechy PITA but tough ribbed stuff. This is plain mid-grey.. and was bought from Zebedees in Southbourne..

I've got some nice stretchy stuff from Megavanmats coming, in Anthracite, (which should be half-way between this stuff and the black I have for the roof), which I'm going to use for all the exposed inner white beams/doors/window surrounds etc etc.
 
#24 ·
Re: Just started to insulate... [pics]

The last pic with the little piece at the top cut out were the handle goes and the surround does that still all go together without it there, as mine was snapped so I made a piece to carpet the little bit and now the handle surround won't stay on
 
#26 ·
Re: Just started to insulate... [pics]

This evening's progress:

Came home from work, and wanted to carry on for a bit, but it was proper cold outside so tackled one of the inner panels, cos I could do it indoors..

Here y'go, for your delectation and amusement:

Wheelarch box:

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Bought some new black screws and chrome caps:

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Passenger side ply panel:

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Assembled:

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In place:

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Thanks for all the comments! I can't wait to get on with this properly, but am going to be away all this coming weekend..

Ben
 
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