Load shelf redux

I've already covered my first attempt at a load shelf, and perfectly serviceable it was too. However, I knew there was a better use of the space.

After scouring the Land Rover forums and eBay I found an auction for an ex army under bed locker. These are often used by the LR boys to make an extending drawer in the back of their Defenders, so taking inspiration I paid out a massive £12 for one box!

Once it arrived I set about it with a tin of paint, I just needed to freshen up the parts that will be exposed once I have fitted and trimmed with Ally plate. I also cut a hole in the hinged lid to fit a drawer handle. I intend fitting a sheet of aluminium or stainless to the top of the lid so I will fit the handle then. I will also remove the original pulls and fit some chequers plate to the front, once the load shelf is fitted.

In preparation for installing in the van, I remade a new battery box and storage trunk which also serves as a support for one side of the drawer, the other side being supported by a MDF upright. Keeping weight down (as much as I can) I drilled both uprights with a large hole saw in a diamond pattern. This is mostly obscured by the carpet and drawer, but makes a huge difference in weight.

Once all of this was roughed out I placed an order to Megavanmats for some black carpet. I was tempted to try the mega stretch but as I don't need to cover too many awkward contours, I went for the regular stuff. This was just fine and I covered the side panels at last...

With the addition of some full extension heavy duty drawer slides the box was fitted, and it works perfectly.

Now I have storage, but also once I have covered the top with metal a cooking surface that is outside the van. This is important not only for reducing the risk of fires but keeping nasty cooking niffs at bay.

Next up for the load shelf is the actual shelf, to be placed across the boxed arches.

So if I'm cooking under the tailgate it would be nice to see what I've doing, right?

Well already in hand, I've reused the LED roof lights I had in my first headlining mod, and fitted them along with another Carling switch in a remodeled tailgate panel. This is done in the same was as the side panels were, and once covered in carpet I think it looks very cool.

The lights set off nicely against the black carpet.

And the switch looks good too, and sticks out only as much as the MDF so is fairly low profile.

Now I just need to make sense of the spaghetti mess at the rear and fit it to the van...

Switch on, switch off

Something else I found on the Mud stuff website was a nice range of Carling switches. I've been trying to find some customizable switches for the various new circuits I'm putting in the van and these fit the bill nicely.

Not only do the types of switches cover all the bases - on/off, on/on/off, mom/off/mom etc, but they take legends in the front illuminated area. All assemble they look factory, so an order was placed (of course) for 1 switch and a 6 way bezel, along with the rear terminal plug and terminals and legends. I only ordered 1 switch for now as I wanted to check fit and finish first.

In the hand these switches really are nice, solid action and well made. This goes for the bezel too.

Originally I planned to replace all of my existing switches with these Carling ones, but as the VW hazard switch and heated screen switch both house the relay too, I've had to keep them original.

I've decided to mount the 6 way bezel above teh heater controls, it fits here perfectly and I've never used the cubby. Having it in line below the stereo helps it look factory, rather than just cobbled together.

How neat is that!

So first up is a switch to isolate the night heater, and also a switch to control the rear fan.

Ever planning for the future, I made up a loom for all 6 switch positions. With my plans for heated front seats I have 2 spares.

And here they are, looking very neat.

Here we have a shot at night, I may change the illumination colour in the future to match VW's.

Keeping the look I will be utilising these switches in other areas in the van.

Bulk-head-lining

All work and no play makes Jack...

I've been working hard lately, just not on the van. Ok, well maybe I haven't been working that hard, but I have been working as many hours as I can get.

But every now and then I get a bit of energy and I get things done. Like the headlining. When I last updated I had covered some hardboard with 6mm foam, and now it was time to recover in the final material.

I had already bought this many moons ago, so no cost was involved as I had some adhesive left over from the carpeting. The material is almost suede to the touch and lends a feel of luxury to an otherwise functional conversion. While I was at it I recovered the nasty front headlining to match.

With the sun visors sprayed satin black to match the black supports it all comes together nicely.

So that was relatively cheap, and the next job was potentially cheaper.

I've been looking out for a mesh bulkhead to fit behind my rear seats for some time. I've looked at genuine VW T4 ones, landrover ones, nearly won a Landcruiser one on eBay too. But no luck, either too expensive or too far away.

Then, as I sat surfing I had an epiphany. Mercedes Vito's are the same basic shape and size as the T4, and they don't attract the "scene tax" as VW's do. A quick search uncovered a mesh bulkhead only 50 miles away. The best bit, £0.99 starting bid with no reserve!

So a late bid was placed, and I got it for 99p!

Ok, a 100 mile round trip costs something but it's still a steal.

In the cold light of day it's about 2 inches too wide. But with swift application of the grinder (my new favourite tool) 4 inches were removed (to make fitting easier) from the middle. I was considering welding it back into 1 piece (with my 2nd favourite tool) but SWMBO made a decree that it should be in 2 halves to make removal easier. This makes sense and now I can still carry long items if I remove 1 side.

To fit the van I bonded some ply (the same used previously for the fan) to the roof in which I had already installed some "wood nuts" (http://thedogvan.blogspot.com/2011/03/boxing-clever.html). As I have laid ply to the floor more of these nuts were fitted there. Adding a small piece of angle to the bottom of each bulkhead, they are now held in play with 3 M8 bolts each.

Rock solid and easily removed, just what I wanted.

I chose a mesh bulkhead as I wanted to hang some MOLLE pouches on it, keeping everything more organised.

I have now removed the dog guard I previously fitted (http://thedogvan.blogspot.com/2011/04/carpet-bagging.html) but might need that behind the drivers seat to stop my dogs from trying to get in my lap whilst driving!