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Sam the T2 Swagman

Discussion in 'Members Rides' started by Nozza, Jul 18, 2018.

  1. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Ventured to the hardware to buy some 9mm ply - went crazy and got marine ply for the seat bases.
    Cut to width, first fit of the base.

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    So far, this was going easily.
    Back in more familiar territory with timber rather than steel.
    Marked the radius, cut, fitted.

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    Drilled holes, countersunk, self drilling screws to fix
    I'm paranoid about things moving after I have measured / marked out.

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    Things going far too well, on to the back.
    Clamps required.

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    Radius marked and cut, fitted and fixed.

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    Things going far too well at this point, I should have been suspicious, and issued another moderate coarse language warning.
    The bed would fold out less flat than before.

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    Not that obvious there, but the timber going 1mm past the steel in the hinge area meant it wouldn't go flat.
    Aware of my ability, or lack of it to repeat fit the ply, I operated on it in situe with jigsaw, rasp and sander.

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    Got it folding back to the original level of flatness.
    And pleased with myself again.

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    Looks like a seat and bed to me!

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    OSF, Jethro, David H and 1 other person like this.
  2. David H

    David H Well-Known Member

    Messages:
    3,555
    Location:
    newcastle
    Small error that I'm sure I'd have made also:(.
    Bloody nice recovery tho':D.
    Cheers
     
  3. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Back to Sam yesterday afternoon, Bathurst going in the background.
    Another problem - the "feet" that hinge down to support the front when in bed mode wouldn't fold down enough.
    Thought I would just have to remove them and round off the corners at the top.
    Closer examination revealed this wasn't the case.

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    The hinge was closed in, not allowing the leg to pivot down.
    But looking closer, the other side was open.....
    What had I stuffed up now?
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    Figured I couldn't have the bases upside down, or the latch to hold it in seat position would be the wrong way up.
    Somehow my hinges, or the latches, had been welded on upside down.
    Fairly quick fix with the angle grinder.

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    All folded out flat now, with legs in place.

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    Back to my mechanic to fit properly to the vehicle.

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    BrissieRex, David H, Syncro27 and 3 others like this.
  4. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Where did October go?
    Sam has little aluminium curtain tracks above all the windows.
    I assumed these were a Swagman thing, and was going to remove them.
    At sometime in his life he had the stretchy wire things fitted too.
    They seemed much easier to make curtains for.

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    But then, with Louise finding photos of how she wanted the interior to look, I noticed the same tracks in a shot...

    curtains.jpg

    Internet searching of "Campervan curtains" and the like revealed they were "Silent Gliss" tracks.
    Discovered the sliders and hooks were available from JustKampers, and after a post here, found the pleated strips for the hooks at Spotlight.
    The tracks stay.
    Returned Sam to the mechanic with a limited list of stuff to be done, a lot I could do myself with more time, but starting to feel the pressure of the Christmas completion deadline.
    Unnecessary but cute set of jailbars for the back window.

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    Seats out again for sound deadening and trimming under and around.

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    New wipers fitted.

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    JK wheel carrier bolted on to replace the old dodgy bull bar carrier.

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    Went away to Mollymook for a week, came back and worry started to set in about progress.
    Wheel carrier had been spaced away from the van to cope with the wider than standard tyres we had chosen.

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    The JK rock and roll bed had been mounted to the floor, but was still not right.

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    But safety latches had been fitted to the pop stop to stop boards on the racks raising it when not planned.

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  5. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Continued...
    Sam has dual batteries, solar panels, and pretty extensive 12 volt wiring.
    This has been finished off and neatened up.

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    Hit full panic mode over the weekend, decided we had no time to go to a trimmer pre Christmas.
    Still need to drive Sam a lot, give things a chance to go wrong .
    Mechanic had done his best to finish the cab area with JK supplied trim bits.

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    The rock and roll bed was still wobbly in bed mode.
    We were thinking of pinning the front supports to stabilise it.
    I revisited the instructions, and found a bit we missed.

    Pages from J14576_-_Rock_and_roll_bed_V2.jpg

    The support along the back.
    Decided the bed frame was strong enough to not need the full width timber, manufactured brackets to support the back.
    The fuel tank behind makes this even less fun.
    Easy to get the brackets to support the seat in bed mode, but they fouled the timber in seat mode.
    Another thing that should have been taken in to account when fitting the seat to the van.
    Ended up with a workable compromise.

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    Sam relocated in the workshop, first good view of his new face.

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    And having resigned ourselves to the interior staying as is until next year,
    And even a bit relieved the pressure was off.....
    Sam visited the trimmer today and he said they can move work to fit Sam in from next Wednesday.
    Head lining.....
    R & R bed and cushions...
    Front seats....
    I will tackle the floor of the back area this weekend, Louise sewing curtains.....
     
    Syncro27 and David H like this.
  6. KahunaKombi

    KahunaKombi Super Moderator Staff Member

    Messages:
    18,747
    Location:
    Bracken Ridge, Qld
    Keep an eye on the 4 mounting points/bolts for the spare wheel bracket around the VW Emblem as others have experienced metal fatigue when using similar mounts :rolleyes:
     
  7. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    After the visit to the trimmer, went to the hardware and bought some bits for Sam's back floor.
    My idea was to level out with ply, cover with vinyl flooring.
    Measured the ply thickness at about 6mm, got three sheets of that.
    Went to the flooring department to be confronted by 97 different types of flooring.
    Timber, vinyl, click together, self adhesive, glue required, indoor only, wet areas...…
    And that is before you get to colour or style.
    Ended up deciding on some self adhesive vinyl planks, limewash timber look.
    Then grid searched the shelves for the correct item number.
    Very stressful!

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    Loaded Sam with ply, planks, tools, wetsuits and paddleboard and headed to Phillip Island for the weekend.

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    Unloaded, cleaned out the load area, laid my ply out.
    First problem - one of my 6mm sheets was actually 9mm upside down.
    Tricky that.
    Blundered on, deal with it later.
    First sheet fairly easy.

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    Marked out some screw positions on the high parts of the corrugations, countersunk the ply and found my self drilling metal screw would go in without pilot holes.

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    The floor level stepped up short of the door in a curvey manner.
    Made a pattern.

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    Marked my second sheet of ply.

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    Cut and trial fit.

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    Not too bad.
    Planed a bit, bevelled the edge, screwed down.

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    Now I was stuck.
    Sunday of a long weekend, wasn't going to find any ply nearby.
    I could wait until later.
    Not in my nature.
    I could stop the floor at the edge of the ply I had - it was almost up to the bed.
    Didn't want to do that.
    Cobbled together my scraps and offcuts.

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    Enough to get my floor to the start of the rise for the engine.
    Quite surprised how straightforward things had been so far.
     
    Wayne murray likes this.
  8. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    On to the planks - progress better than I expected.
    They were "repositionable" self adhesive, with quite awkwardly two planks sharing a piece of backing paper back to back.
    The "repositionable" seemed to mean the adhesive wasn't quite strong enough to hold them down, but plenty strong enough to pick up any dust or dirt.
    Started at the furniture run, ignoring the instructions to start in the middle of the room.
    Don't think my area is big enough to matter.
    Meant to cut them with a Stanley knife, which was putting my fingers in danger.
    But first couple down, going well.

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    Switched from Stanley knife to jigsaw for cuts

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    Continued to the last plank.

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    Things are going a bit haywire computer wise, will continue.
     
    Wayne murray likes this.
  9. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Pleased to discover the last plank was a parallel 115mm strip, apart from notch outs for the door.
    Not only must Sam be square, the original furniture and my plank laying was square too.
    Or it could have been luck.
    Final plank.

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    And at 6.00 p.m. or so, there I should have left it.
    But I had an edge strip to fit.
    Figured I would screw through the strip and the plank, in to the floor, hold everything nicely.
    Started to drill, realised my plan would leave screws poking down in to the sliding door track.
    Not such a good plan.
    Decided to just screw in to the last plank, then glue the edge strip and last plank down later.
    Took the edge strip to my bench to drill.
    Tougher than I expected, rested on the edge of the bench.
    And broke the drill bit, poking the broken end through my finger nail and finger.
    Said "Golly, that hurts" or similar, selected the nearest bit of rag to staunch the blood flow, got a beer out of the fridge and retreated to the back decking for first aid.
    Blood flow slowed in the time it took to drink a beer, The Wife One dressed the wound.

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    Throbbing somewhat, returned to the edge strip.
    Drilled some holes without further drama and screwed to the last plank.

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    Only sign of the mishap is two screws close together in the middle.
    Checked inside.

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    All good.
    Will just have to re visit the last plank and edge strip with liquid nails or something.
    And crawl under to seal the screws poking through.

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    Very pleased with the look.
     
    David H likes this.
  10. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Wasted most of a day wrestling with fridge mounts.
    Tom the mechanic had mounted it on rubber mounts pre my floor laying.
    I drilled up through the mounting holes, drilled out the ply and planks, adapted the mounts and studs, re fitted.
    And it wouldn't line up and the studs were too short.
    Left it for Tom to re do, watched replays of the car racing from New Zealand.

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    Decided the up side of my incorrect ply purchasing was I could make a front for the seat / bed.

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    The 9mm ply would be fine for that.
    Aware of my limitations, decided to make a cardboard pattern first.
    Had to go and buy more pattern making cardboard first.
    Measured, taped together.

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    Cut out slots for the latches.

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    Added some slots for the support legs to go through, marked on ply.

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    Cut out, trial fit.

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    Not going to get too fancy with this, time is short.
    Could access the storage by lifting the bed, or make doors for the front.
    Lifting the bed a bit awkward, doors too hard, went for some access slots.
    Traced the support positions on the back of the ply, marked some openings.

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    Cut out the openings, wondering why I am still using the blade that came with the jig saw?
    All went OK.

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    Screwed in.

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    Did a photo shoot to see what things might look like when the seat is trimmed.

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    Will remove and varnish it while Sam is at the trimmers.
    And make a timber cover for the fridge too I hope.
     
    KombiEvie, David H and Wattie like this.
  11. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Sam delivered to the trimmers last week, varnished my seat front with limewash varnish.
    Found it difficult stuff to work with, but came up OK.

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    Made up a cover / cabinet for the fridge, lime washed that too.

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    Probably another coat or two to go on that.
    Got a message that the trimmer had started on Sam's headlining.
    Old stuff stripped out.
    Stopped in for a visit and surprised, pleased, amazed at how rust free Sam is in the roof.

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    New headlining starting to go in.

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  12. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Two weeks down the track, I have been away, went to check on Sam.
    Instruction had been not to start anything that could not be finished today.
    Headlining done.

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    Rear seat trimmed.

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    And bed cushion done.

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    Front seats will have to stay as is for now, but really pleased with how much they achieved, and how good it looks.
     
    David H and Wayne murray like this.
  13. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Fitted my limewashed seat front this morning at the mechanic's

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    Left them to it to fit the fridge and a new exhaust I ordered from Just Kampers a long time ago, that arrived a while ago.

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    My inner hoon has escaped.....

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    melissa likes this.
  14. chris taylor

    chris taylor Well-Known Member

    Messages:
    1,641
    Location:
    adelaide sth aust
     
  15. chris taylor

    chris taylor Well-Known Member

    Messages:
    1,641
    Location:
    adelaide sth aust
    By the way Nozza, great photos, i especially like the bed set up and the clamp down thingos, Will keep watching with interest....:)
     
  16. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Went to the mechanics this morning to make sure Sam was ready to collect.
    My inner hoon is well and truly out and about.

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    Looks good and has a nice note without being too loud.
    Fridge is mounted and cover on.

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    I'll get him back this afternoon, do a couple more things, then call him finished until next year.

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  17. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    While waiting to collect Sam I went to Kmart and bought a microwave and sandwich maker for him.
    Low powered enough to run from his 240 volt inverter.
    Collected him, stowed a jack and wheel bar in the spare wheel well under the bed.

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    Loaded paddleboard and gear for Saturday.

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    Down to the local Saturday, enough shelter to hide from the wind along the shore.
    Sam waiting patiently while I did the water check.

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    While I was packing up after a nice paddle, another Kombi owning couple stopped to chat and admire Sam.

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    Really enjoyed the morning with Sam.
     
  18. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
    Saturday afternoon over to my factory for some final touches.
    Stopped at the hardware and bought some 6mm ply for over the engine.
    Made a pattern, cut and fitted.

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    I had to do it in 4 pieces to achieve the shape.
    I'll fiberglass it together and lime wash it later.
    Raised the pop top to give some working room, discovered the trimmer, without being asked had made new hold down straps, repaired window zips etc.
    Nice to find someone who cares.
    Things are going haywire again, I'll start another.
     
  19. Nozza

    Nozza Active Member

    Messages:
    185
    Location:
    Melbourne
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    Screwed a crockery holder Louise had bought to the top of the fridge.

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    Dredged up skills learnt while working my way through Uni moonlighting as an electrician.
    Cut the cord on a powerboard, drilled holes to thread it through to the old gas cupboard that houses the inverter, re joined with a junction box.
    Cut and bent some punch strip to screw the microwave to the bench top.
    Glued the power board to the top of the microwave.

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    Sam has a 1000 watt 240 volt inverter, connected to the auxiliary AGM battery housed in the old gas cupboard.
    He has no on board gas or stove, just a removable two burner stove running on butane cylinders to use outside the van.

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    That's the inverter and junction box.
    Fitted Louise's mirror to the wardrobe door.

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    Sunday I got some twist lock poles for the awning, mounted a fire extinguisher opposite the inverter, added a fire blanket and water tank.
    And had to admit I was needlessly bimbling because I didn't want to let Sam go.

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    Awning, ropes and pegs under the bed, poles in the wardrobe.

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    I had to get rid of the timber edging on the bench to let the microwave door open. I can see a timber bench top with sink cover as a future project.

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    Delivered Sam up to Louise in St. Kilda so she could start shakedown cruising him.
    The first being the drive to Torquay to work this morning, leaving at 7.00 a.m.
    Worried how she would go, only her third drive of Sam, she got there no worries.
    Despite describing the drive as "terrifying" in Melbourne and Geelong peak hour traffic.
    Here's Sam in her work car park.

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    Hopefully she will keep me updated on her adventures with Sam.
     
    Wayne murray likes this.
  20. chris taylor

    chris taylor Well-Known Member

    Messages:
    1,641
    Location:
    adelaide sth aust
    Hi Nozza ,great photos,been a pleasure to see them, like your idea of a exterior cook stove. have gone down that path myself when on the 2018 Bus Stop at Stanthorpe.Did not use the internal gas stove at all , { away for 11 days }. The single burner stove is great. Looking at the interior, is it a fibreglass set up.
     

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