BUILD -The Final Works

Its been a busy time. Not sure where March went. We came back from our bushcamp shake down trip with a list of things to do. Apart from the obvious of sorting out the storage areas, we appeared to have an issue with the electrics. The solenoid for the truck battery was getting VERY hot, the Enerdrive system was charging from the truck batteries even when the engine was turned off and the suitcase solar panel ia the external anderson plug didn't appear in the simarine. Upon our return Justin came back and made a few changes.. a new stronger 24v solenoid to isolate the cab fuse box and another to isolate the main batteries from the DCDC charger. 

Now we had to make sure we had everything done for the engineer, Rowan Carter from Cartech. We went through the regulation check list that is required to have to be a motorhome. We thought we ticked all the boxes even designing a seating plan sticker as per regulations. Unfortunately we still did not pass on our first inspection! 

The 6 reflectors were easy enough, we just had to stick them on. The other issue was the laminated glass in the bathroom door and the acrylic in the Aussie Traveller side door not comply with the AUTOMOTIVE glazing standards (ADR 8/01 rating). Rowan made some suggestions of places that could provide what we required. After a bit of research and many phone calls, we decided on the a Shinkolite acrylic 6mm sheet that we sourced from Mulford Plastics.

Finally due to the Shinkolite being clear we bought an obscure film to put on the bathroom door for privacy.

So 2 weeks later, at the end of March, we had our VASS Approval Letter from the engineer. Next was to get to a Vicroads that would inspect Heavy Vehicles. We were assured that we did not need a booking and so drove the next day to Dandenong. Unbelievably when the VicRoads inspector came out to measure the truck, the measurements were 100mm longer than we had. When we asked them to remeasure we noticed that the tape was missing 100mm from the end! Anyway we went back inside and had to wait another 30 mins while they checked whether we needed a Blue Mod Plate from the engineer. Eventually they worked out that because it was just a letter of approval and not a certificate we didn’t need it and so our Isuzu 'Caravan' (as per registration paper) was born and we have named him  BUSTER.

What a relief to get that done. Now we could get fully insured. We decided to go with CIL (previously the tray truck was with RACV) which was $1900/$1000 excess per an ($500 less than Ken Tame which had $2500 excess and no free windscreen replacement). 

During this time Mark kept busy with other projects. 

The 3rd water tank (45l originally to be our waste water tank) at the rear was fitted with a tap which we will use as an outside only water source not connected to the pump. We fill up the tank via the tap.

Next was sorting out the under bed storage area.

Mark made a set of draws with self locking slides for some of his tools. 

He made shelves for the camp cooking equipment. 

Then he used some acrylic sheet to make a barrier to protect the heater.

He secured on the bed frame a pole saw, extra UHF aerial, broom etc. Overall it’s all nice and neat with room to spare for a recycling bucket and laundry bag. 

Mark bought a set of maxtrax mounting brackets to secure them on the roof rack instead of having them inside the tool box with the other recovery gear from Sherpa. 

In the other tool box Mark made a box for the BBQ to be secured during travel. Mark then put a partition in for chainsaw, breaker bar for the wheels and wooden jacking blocks and impact wrench.

The centre console was designed and made from left over ply used for the cabinetry. 

he UHF radio was wired in the bottom of it and 2 USB plugs for charging up. 

We bought a Englaon 12v 32” smart TV and a TRA TV bracket  which we set them up one in the dinette area and one near the bed. I cut down an old canvas bag and lined it inside with a quilt and some silk to help protect the tv. We were happy that it fitted nicely in the cupboard behind the dinette seat.

We found the suitcase solar panels we had were either too big or too heavy so we purchased a 200w Itechworld blanket solar panel that fits nicely in the same cupboard as the TV.

We stuck a mirror on the bathroom cabinet. 

The Lagun table leg was not strong enough to hold the table up so we bought an adjustable foldable leg to make it more sturdy. 

We wanted the minimum devices attached to the windscreen as we bought a Solarscreen and didn’t want to be having to take the devices on and off every time we put the screen on. So Mark used some acrylic sheet on the side of the overhead storage to attach the tyre monitor.

 We bought a flexible goose neck mount for the GPS that also sticks on some acrylic in one of the shelves. 

The dashcam and etag were small enough to stay on the windscreen.

Mark then glued the metal surround we got water jet cut and then powder coated for the crawl through. 

Now we are finally ready to pack and take Buster on his first road trip…

 

BUILD- Finishing

The countdown was on, we only had 7 more days to be ready to depart for our first adventure, 1 week bush camping at Sheepyard Flats on the Howqua River near Mansfield with a group of friends.

The bed frame was completed and the double mattress put in its place.

The kitchen benchtop was readied for the oven to be installed when the gas plumber came to do the gas install.

His work consisted of the gas regulator and hoses for 2 x 9kg bottles, a bayonette fitting for the outside BBQ and plumbing in the oven. We were then issued with the much needed Gas Certificate for the engineer.

We bought Fusion-Loc towel rail and caddies from Bunnings and built the mirror cabinet to finish off the bathroom.

We finally covered the internal steps with some leftover vinyl. We used double side tape to and then an aluminium angle to secure it all in place.

Mark machined up some old timber we had at home to make the table top, which I stained and put 3 coats of polyurethane.

 The table works great on the Lagun swivel leg.

We asked our friend Ray and our son Tom, to help to install the Dometic awning. Mark screwed and siliconed on the track before they slid the awning onto it. Then the legs were secured onto the body.

The final outstanding items for compliance were the clearance lights. 

The last item that the engineer required was to get the trucks Tare Weight. So we drove down to a public weigh bridge in Dandenong. We paid $40 at the automatic machine and got a certificate specifying the total Tare weight of 5.44T (front axle 2.46t, rear axle 2.98t) with 70l diesel and 85l water.

 

Mark lined the floor in the storage area under the bed with a rubber mat for now (will fit it out properly when we get back home) and began packing for our trip.

We bought some containers from Kmart for the overhead cupboards inside which fitted well and managed to pack all we needed and some with plenty of space to spare.

Finally, after 2 months of working on the truck nearly 7 days a week we now had a functioning motorhome. Yoo Hoo!

We will review how everything went in the next blog....

BUILD- Plumbing and electric fitoffs

We push on with the build, concentrating on the plumbing. Mark fitted inlet pipes to 2 of the 3 water tanks. The tank 1 (front) is 170L and tank 2 (middle) is 85L. 

The 3rd tank (back) is 40L and will not be plumbed into the water system and will be used as an outdoor tap. It was also originally going to be our waste/grey water tank but we couldn't get the fall required to it. This is why we built a waste water tank into the bottom of a tool box. Mark finished fitting the waste pipe to this box.

Next Mark had to cut the bench tops to fit the sinks and the oven. The waste pipes were finished off to the sinks.

Then Mark installed the water pump bringing the water separately from Tank 1 and 2. There is a filter connected only to the cold water hose going into the kitchen tap. We also have a inline filter for when we are filling up from dubious water sources. 

Then the hot water heater, bathroom tap and shower heads (bathroom and external), were all connected.

Now we installed the bathroom door from The Showerscreen Factory in Epping. We were very happy with the features of the door including the opaque glass, travel lock and water channel.

We also fixed a rod up for a shower curtain to mainly protect the heater fan head fitted in the vanity.

Finally Mark put silicone on all the internal edges and around the vanity and toilet.

In between the plumbing being done, Justin and Mia from Lumitec came for the final fitoff. 

A solenoid was fitted to connect the cab fuse box only after the truck has started. We also installed Victron trickle charger for the truck batteries.

Mark brought through the wires for Safety Dave's reversing camera and the UHF radio which connected to the fuse box installed in the cab behind the dash.

Another project we accomplished was the curtain for the crawl through. We managed to find an anchoring point that we could drill into just above the opening. The upholsterers that made our seat cushions, kindly gave us some extra material which was used to make the curtains. The material was quite thick and has good blockout as well as matching the dinette.

Other tasks this week included, cutting down the mud guards, putting the rubber seal around the door and finishing off the cabinetry of the dinette cupboards.