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Discussion Starter #1
Hi all. It's about time I sorted a build thread - I've had my white 64 plate SWB T5.1 for just about a year now and the interior has gone through quite a transformation (shame about the exterior!).

The first 5 months of owning the van was where most of the work happened, so it's gonna take a while to upload everything (especially because for some reason I can only access files going back to July ?). I'll probably add a few posts to bring you all up to the current day...

So, here goes... It's a 64 plate SWB T5.1 (T32), had around 106k miles when bought (and only has 1k more now as it's not used much!). It was sold to me with FSH although didn't have much paperwork as it was previously a fleet vehicle from what I can tell. I do have some receipts however. It's a basic spec, so 2.0 TDI (84) Startline 5spd manual.

Day One:

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I was really pleased with just how clean an example it was/is. The first job when I first got it home was to give it a nice hot bath followed by a good old clay bar session. There were a few bits of rail dust/tiny rust spots that annoyed me - these all came off with the clay. I used a Meguiar's 'Quik Starter kit' in case anyone is interested.

I'll add some more updates soon...
 

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Discussion Starter #2
Next up we started the tedious task of unscrewing/unclipping the panels from the interior:

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And then we had someone come and fit some side windows... but there was an issue - the van had previously had additional deadlocks installed in the side sliding door which needed to be removed...

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And the windows went ahead...

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Now it might sound unusual... but we chose to have 2 windows installed on the drivers side, but only 1 on the other side in the sliding door... this is why you shouldn't listen to your Mrs... there was some rationale mind, as that is where we'd planned to build a unit for TV/storage, so the window would have been a waste, but I still think it was a daft decision haha. I'll probs get some vinyl fitted in the space so it doesn't stand out as much.
 

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Discussion Starter #3
Next up on the list was adding 'Silent Coat' sound proofing. This was handy as it came with a sticky side, so was super simple to fit. I bought a roller too, which came in very handy!

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I tried to get good coverage on the sides, barn doors, roof and wheel arches.

Next I decided to man up and get the floor out... and it was as I suspected, absolutely stinking!

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All clean (or at least 50% was haha):

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Discussion Starter #4
Next up:

  • More cleaning
  • Foil bubble wrap insulation - stuck using spray adhesive (get a face mask!). Also worth mentioning Foil tape comes in handy to get a neat finish and really make sure the insulation is stuck down.
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Discussion Starter #5
So, with the old floor up and everything clean, now was a good time to start the foundations for laying a new floor. I layed strips of wood to make a nice level base for the new floor to lay on (and be drilled down to).

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This isn't some crazy art haha. I used some building materials lying around to make sure everything was held in place...

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I later found that this was nowhere near enough so added more strips of wood in any remaining gaps.

I then added more insulation:

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Discussion Starter #6
Next up:

  • Insulating the floor
  • Cutting out a new floor
  • New DRL bulbs and black badges
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Kept the old floor to draw around it... just had to make sure it wasn't upside down or anything.

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Wasn't perfect and need trimming down, especially when the carpet was fitted as it was too tight.

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Ironically these lights just stopped working so I've bought another set off Ebay...

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Discussion Starter #7
Next up, I took down the old ceiling? Or roof lining? Never know what to refer to it as!
Then I added.. you guessed it, insulation.

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Then it was time to start carpeting the van. I started with one of the barn doors and I must admit, it was one of the worst jobs. Now I know why a lot of people just flat out don't bother insulating them! My technique was to start from one of the top corners and work your way down, but to be honest there didn't seem to be a 'right' way of doing it. With both doors I ended up with a huge crease at the bottom, so had to make a cut and join in the middle.

You might notice the edging (left hand side and top) is quite neat.. it wasnt originally so I cut a long strip of around an inch in width of fabric and stuck it on the edge to finish it off nicely.

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This was eventually the finished door:

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Discussion Starter #8
Next up...

I started carpeting the interior of the van. I havent mentioned yet but this is the '4 way stretch' fabric. I'd recommend getting a pal to help when doing this.. don't think I would have done it on my own at the time. I also did a bit of prep work and covered the windows in newspapers, not to get spray adhesive on them. I started from the top and worked my way down with this task.

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Next, I bought a wiring kit from Rayne Automotive and set about laying out the wires and planning my next steps around this.

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I then did the other side of the van...

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Discussion Starter #9
Next up:

  • Carpeting the headlining (front cab)
  • Starting work on the wood ceiling
Seen as I appeared to have a load of carpet leftover, I thought it would be a nice touch to give the cab headlining a fresh bit of fabric. I made a judgement that I'd regret - deciding to take the old carpet off. If I was to do this again I'd just glue the new fabric over the old one... it genuinely took me hours to get the old one off!!

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And fitted:

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Then, time for what I feel is the most unique part of the build, the wood 'ceiling'... You'll see the batons of wood going from side to side, fixed with self tapping screws. The LED wires all routed neatly above the 'ceiling'...

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I decided to keep the original lights, but moved them both to the centre...

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Discussion Starter #11
I'll leave it at that for now. My fingers are aching from using my phone lol. Will post more tomorrow.
 

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Amazing work this far mate, love how your ocd is at the point that the bricks were laid mirroring each other almost 100%, sort of thing I'd do ?
Look forward to seeing what's next (y)
 

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Discussion Starter #14
@Pduk

?? OCD is basically the perfect term. Funny thing is I'd never thought about how uniformed the bricks were until now hahaha.
I'll upload some more pics later on ?
 

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I just saw them and thought wow that's some impressive setting out right there ? (y)
 

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Are you fitting storage cupboards in the back too, or you going with a full width sofa bed?
 

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Discussion Starter #17
@Pduk the plan was to have some storage. So basically imagine you're looking in to the van from the rear with the back doors open - the bed is on the right hand side (pulling out to the left), it won't be the full length. There's going to be around a foot and a half of space behind the drivers seat. That's the space I've left for some storage and potentially fridge/hob, although I havent thought that far yet...

On the left as you're looking in through the back, there'll be some units there with a mains plug and TV.

That was my original thought process, the other thought thought this would be a good idea for some reason, but I must admit I wish I'd gone with the more conventional design of storage units down the right hand side and the rock and roll bed on the left!
 

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Discussion Starter #18
As promised, some more pictures of the build so far. After the 'ceiling' was almost completely finished it was to crack on with the floor...

So I started by taping over any joins and also for photographic reference, drew on the floor where the supports were underneath (I thought this would be useful to refer to as a reference when I need to drill down and fix units/bed)...

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Then I bought vinyl flooring, which matched the 'ceiling' quite nicely... as the floor hadn't been drilled down it was easy to take it out and use it as a guide to cut the vinyl to size...

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I then cut off any excess and made it fit...

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It still wasn't all fixed in place at this stage, but I'd bought myself the full length threshold cover, so decided to test it. Much better!!

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Discussion Starter #19
So we're almost up to date now, the van hasn't changed a great deal since around August last year. LEDs were fitted to the 'ceiling', wires were routed as neatly as possible behind the seatbelt plastics etc... I made a box for the leisure battery/split charger/fuses.

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Managed to route the wire from the leisure battery to main battery, around the back of the seats, up the side of the passenger seats under the mat and through a grommet...

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Then the van finally got a bit of use last July when I did a big mountain bike ride from one side of Wales to the other ?.

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That was that until this year basically. The van had a slow puncture, turned out the wheel was a bit flat so bought another steel wheel to replace it and decided to paint them black... only got around to doing 2 so the van is like Jekyll and Hyde at the moment lol...

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And there we have it. I'm in the process of building a pull-out bed so will post some updates in a bit.

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More cracking work there bud, quite funny how similar our journey's are so far, as I too loaded my bike into the empty back and headed off to Wales for a holiday (y)
Originally I was all set to buy a rock and roll bed and get the electrics installed by a company, but after going to a few shows and seeing non standard installs I felt this is the way to go. Keep pushing forward with your bespoke design, will bring such a feeling of accomplishment wen you're done.
I may have to pick your brains regarding the leisure battery install at some point if that's ok? ?
 
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