Fitting out the interior (part 1)
This was probably the step we underestimated the most. We thought once we had a fully insulated waterproof habitation box on the truck we were over half way but the reality was very different. Carpentry takes a lot of time and precision and no matter how many time you measure up it will never be exactly square. Gas-work is anxiety inducing and don't bother ordering a pipe bender, springs work just as well. Sizes seem to be a mere indicator in plumbing, someone please pick between metric and imperial. And god knows why somehow you still find yourself welding every other day. Regardless, the truck is now starting to feel like our little home/nest and that feels pretty great.
Below is a list of the items we started with. We built in order of priority to reach a minimum viable product as early as possible which basically meant completing the DVLA campervan requirements first.
- Bed: timber and steel leg supports, 12mm plywood base reinforced with 25mm plywood slats underneath, 25mm plywood runners added on top down the length or the mattress to allow airflow, and standard Ikea bed slats screwed into that (we recommend putting neoprene tape under the bed slats before screwing them in as otherwise the bed is VERY creaky),
- Cooking area: 44x44mm timber frame, 12mm plywood for shelves and support, fire boards around gas oven and under gas hobs, copper pipe running to gas cupboard with aeration vent, countertop made of 3 Ikea chopping boards held together by 12mm plywood board,
- Seating area: 44x44mm timber bench frames with 12mm plywood panels, one of the benches includes a shoe cupboard to the side and both have lids on the top for storage, table make out of 25mm plywood, 60mm box section steel cut to height, and post shoes bolted onto the habitation floor and table top (to enable changing the table leg and dropping the table down to a sleeping position),
- Sink: 44x44mm timber frame with sink attached to 25mm plywood (varnished with 5 coats and sanding in between), sink resting on 12mm plywood shelf,
- Water tank: 350l tank strapped securely into a 40x40mm steel frame bolted directly onto floor and main habitation box frame,
- Bathroom: 44x44mm timber frame with 12mm plywood and quarter round, 80x80cm quadrant shower tray and Thetford cassette toilet.
Below is a summary video of our first efforts to make our box habitable. There will be more.
Below is a list of the items we started with. We built in order of priority to reach a minimum viable product as early as possible which basically meant completing the DVLA campervan requirements first.
- Bed: timber and steel leg supports, 12mm plywood base reinforced with 25mm plywood slats underneath, 25mm plywood runners added on top down the length or the mattress to allow airflow, and standard Ikea bed slats screwed into that (we recommend putting neoprene tape under the bed slats before screwing them in as otherwise the bed is VERY creaky),
- Cooking area: 44x44mm timber frame, 12mm plywood for shelves and support, fire boards around gas oven and under gas hobs, copper pipe running to gas cupboard with aeration vent, countertop made of 3 Ikea chopping boards held together by 12mm plywood board,
- Seating area: 44x44mm timber bench frames with 12mm plywood panels, one of the benches includes a shoe cupboard to the side and both have lids on the top for storage, table make out of 25mm plywood, 60mm box section steel cut to height, and post shoes bolted onto the habitation floor and table top (to enable changing the table leg and dropping the table down to a sleeping position),
- Sink: 44x44mm timber frame with sink attached to 25mm plywood (varnished with 5 coats and sanding in between), sink resting on 12mm plywood shelf,
- Water tank: 350l tank strapped securely into a 40x40mm steel frame bolted directly onto floor and main habitation box frame,
- Bathroom: 44x44mm timber frame with 12mm plywood and quarter round, 80x80cm quadrant shower tray and Thetford cassette toilet.
Below is a summary video of our first efforts to make our box habitable. There will be more.