Building The Battery Box (Part 2)

This weekend I finally found time to do some more work on the cabinet in the back of the van.  My pal Terry and me spent the entire day working on it and it's still not finished, but is really taking shape now.  This is where it was when we last left it, and this is just propped up against the wall, not secured in at all.

First thing we did was to compartmentalise it so that there were specific sections for (from left to right) the 12v cool box, mains charger and leisure battery to fit into:

Then we built the rest of the framework.  This took some time as we had to cut and shape it to fit the curved wall panel.  Fortunately Tel is a professional and knew what he was up to!   A template for van furniture would have saved us hours and hours here though.  I wonder if you can get them on the net anywhere...

Then it was time to fit it onto the panel itself.  For this we used 6 fixing brackets like you use to build kitchen furniture.  This makes it really easy to take off the panel if required.

Then we put the sides and top on.  Again this took a long time as we had to cut the ply to exactly fit the contours of the van walls.  Not simple.

That is pretty much as far as we got.   We started messing around with the piano hinges we bought and after some discussion and trial and error worked out how we will fit these to make the two doors on the front, but we ran out of light to fit them.  So, still left to do:  

• Cut and fit the two doors, including latches.
• Stick the drivers side stereo speaker into the side of the cabinet.  
• Fit a double 12v socket into the side of the cabinet somewhere.  
• Figure out where the mains hook up is going to live inside all this.
• Fit a double 12v socket inside for the 12v cool box to plug into.
• Fit the split relay charge system inside somewhere.
• Wire it all together.

Hopefully we've no more than a few hours left to work on this and we're done.   I'm still hopeful it will be complete before the van goes in for the elevating roof and carpet fit at the end of March.    I might not have it veneered by then but that might be best left till it is all carpeted anyway.

Slow progress but we're getting there.

Plywood Rear Panels In

I picked the van up from the garage today with two new drive shafts, and as soon as I got it home I got the rear plywood panels in.   We'd cut them at the weekend from 6mm ply but had found the default plastic rivets weren't strong enough to hold them in place.  So I ordered 40 scrivets, which are blinking excellent.   

I popped the old hardboard panels off using the usual rivet removing tool and simply screwed the new panels on using a electric screw driver.  You can hammer the scrivets in and screw them out but it was even easier to just screw them in.

Then it was time to slot the rear cabinet frame into place and see how it sat.   The frame is only really half built but at least this gives me an idea of what it will look like when completed.

So now all that's left to do is work out how to attach the frame to the plywood panels, finish off the frame, board it up with plywood, add latches, hinges and such, cut out the holes for the 12v sockets and then finish with wood veneer.  Easy!

Double Drive Shaft Failure

So, the van is in the shop to get the driver's side drive shaft fixed after the breakdown on Sunday.  They've managed to replace it, which is good, but whilst checking it over they realised the passenger side shaft is also screwed.   No details from the garage yet as to what has happened to the two but it's a tad annoying that they have both failed within 21,000 miles of use.

Still, on the plus side, that's two new drive shafts both within warranty and basically for free.  And fair play to SMG Cowfold for fixing one and noticing that the other was broken.  Also VW Assist were really great - they came and picked the van up from my road and gave me a hire van for the time the van was being fixed. Again, all for free and just because the van is still in warranty.

Hopefully I get it back tomorrow.

I also took delivery of my new "scrivets" today - so tomorrow, if the van does come back I'm aiming to try and fit my new plywood replacement panels in the back.  Should be good.

Continuing Cabinet Design

Been thinking some more about how I can finish off the cabinet design and I've had some more good ideas that I need to write down before I forget them...

The cabinet has been built in two sections. The lower section boxes in the wheel arch and the upper section is big so that it will house my battery, charger and cool box side by side. The coolbox is about twice the height of the charger and battery so there is a large space above the battery and charger at present.

My idea now is to partition the top area in two: one for the cool box and the other for the battery and charger. I'll then stick a shelf in above the battery and charger making a further storage area and having the effect of isolating the battery and charger in their own little box. This section can have a plywood panel screwed on the front so that the battery and charger are hidden away but can be accessed by unscrewing the panel. Sounds good.

Regarding power points, I'll put one double 12v socket into the upper shelf such that the 12v cool box can be plugged in here, and one spare appliance too. I see us charging mobile phones and stuff here, hidden away with the door shut. Nice and neat. Then I'll stick a double 12v socket down in the lower wheel arch section coming out of the front into the main van. This front section will be hinged and made into an access door. I don't expect to open it often but it will be possible to do so if desired. This double 12v socket provides power to the main van when needed.

When the 240v hook up goes in this can feed into the lower, wheel arch, section. In there we can put a double 240v socket on the hinged lower door, next to the double 12v socket. This will give 2 sockets into the van. Then we can stick a third socket inside this lower section, hidden away. This socket will take the mains charger plug so that when the van is hooked up the leisure battery will automatically be charged. It will all be hidden away in the lower compartment this way. Neat. I'll need a hole in the shelf inside the battery area to drop the plug and wires through into the wheel arch section but that should be hidden away as well.

The two front panels will be hinged at the bottom using piano-hinges. These give the best support as they can run along the whole length of the door. The top most door, which will cover the entire upper section, will be supported by chains which will stop the door opening at exactly 90 degrees. This won't be super sturdy but should provide a strong enough work surface, when opened, to stick a kettle and some mugs on. This should make a handy addition to the cabinet.

When it comes to finish, I was thinking of just getting it all carpeted over, but I'm now thinking I might cover it with stick on wood veneer to make it look somewhat professional. The jury is still out on this idea but it's simple enough to do and could make for a good looking cabinet I reckon.

With this design I get:

• A lower wheel arch section into which most of the electrical wires will be housed and hidden. There will be space in here to store quite a bit of spare stuff - I'm thinking I'll probably stick spare bungees and stuff like that in here.
• A battery/charger compartment what is hidden away but accessible easily by removing some screws.
• A cool box section which is big enough to slide the cool box into whilst having it safe and secure when driving. It should just about be big enough to open the cool box whilst in this location too.
• A spare storage location above the battery box, which has a double 12v socket in it for powering the coolbox and another appliance. I envision storing a 12v kettle and some mugs in here.
• A pull down door on the front of each section. The top one will be supported by chains so that it makes a nice shelf/workspace when opened.

Just got to get on and finish building the thing now!

If only everything in life was as reliable

This morning on the way to drop my pal home the whole van started to shudder violently. It felt like a wheel was about to come off. I quickly pulled over into a handy lay-by and we checked out the wheels. They all seemed to be fine, so we started the van up and she started okay and revved fine in neutral. But as soon as I tried to put her into any gear she shuddered and screeched. It seems the tiptronic gear box might have gone. However the mechanic who towed us home told me he thought it was the drive shaft. This seems to be confirmed by my neighbour who also has a T5 and told me they were a very common fault.

I've owned the van 1 week shy of 6 months and the van isn't yet 3 years old so I'm sure I can get this fixed under warranty. It's just another frustrating thing on top of not being able to finish off my battery box yesterday.

But on the plus side I broke down only 10 miles from home and within 55 minutes of pulling over crock, I was back home, with the van parked up outside the house. Awesome service from Insurance Choice Breakdown I have to say!

If only everything in life was as reliable as a Volkswagon? Hmmm.

Building The Battery Box (Part 1)

This has been one really frustrating weekend. In a nutshell we couldn't finish building the battery box as was planned, and also the van broke down in a big way. Rubbish. Anyway, this is what we did achieve:

I went up to my good mate's house first thing Saturday morning and we set to building the battery box. The first order of the day was to replace the two rear hardboard panels with 6mm plywood. Thin enough to bend but thick enough to provide some support to the battery box frame. We went to the local wood supplier and bought two huge sheets of ply and a few 2"x1" planks for building the frame for the box. We also picked up a ton of screws. But we were unable to find a couple of piano-hinges we were looking for. So we knew the doors to the box would have to wait for now.

We got back and marked out the two panels in plywood.

Then with the help of my mate's electrical carpentry kit and his expert knowledge we whipped around the template with a jigsaw. Well, he did.

Net result, a pair of rear panels almost ready to go in.

Before they could be fitted I drilled the holes through which the plastic rivets would pass, and did a lot of sanding. No one will get a splinter off these panels!

This was when we hit frustration number one. The panels would not go into the back of the van. As far as I could see the template was fine and all the holes lined up okay. The issue was that the default VW plastic clips were simply too short to bite properly with the thicker and less flexible plywood. This simple problem totally threw a spanner in the works. Not only did it mean we couldn't finish the job in one day (which would have proved impossible time-wise anyway as it turned out) but we couldn't completely work out how we would attach the box to the panel as we couldn't fit the panel in place.

Anyway, undaunted we continued on with the work. We measured, cut and built the beginnings of the battery box. This was one construction by the time it was done but was made of loads of bits of 2"x1" for the frame, plywood to cover, and to make the shelves, and a gazillion screws. It comprised a box to cover the rear wheel arch - this box will also hide all the electrical wiring when completed - and an upper box into which we can put the leisure battery, charger and 12v coolbox. Sweet.

There is some space spare for more storage and there will be easy access to everything via latched doors on the front of the box. We still plan to have a double 12v socket on the front, and one inside the box so that the 12v coolbox and one other appliance can be plugged in, out of sight. When the mains hook up is added a double 240v socket will be put on the front and one 240v socket will be inside, for the mains charger to plug into.

I didn't take a picture of the final state of how far we got the box at the end of the day as we were in a rush to get on and watch the England vs. Wales Six Nations match (one bit of good news in the weekend!). I'll edit this post and stick one in tomorrow when I have some daylight.

Anyway, I've just ordered a bunch of double length replacement plastic rivets and as soon as they arrive I should be able to install the plywood replacement panels. Then it's time to arrange to get back to the mate's house and finish off the box.

Mains Hook Up

After chatting to the educated and enlightened chaps on the Brick Yard forum I have decided it is much more sensible to get a professional outfit to install a 240v mains hook up into the van. 12v electricity is relatively okay to muddle about with, but 240v can be deadly so it's important. To that end I've just arranged with CMC that they are going to add in a mains hook up the van when they do the roof. They are also going to wire a couple of 12v LEDs into the leisure battery at the same time.

It makes a lot of sense to me to get these done at this stage, so that they can do all the faffing about with wires and then finish off with the carpeting. So there will be no need to pull the carpet up to fit stuff later.

When the van comes back from CMC it will almost be ready to sleep in!