Your Wife is the perfect assistant, knowing when to help and more importantly when not to help. Great videos I know there 5 years old but there still solid information.
This is just outstanding. It is as close to what you would see in a coachworks, professional upfitting shop. It's also simple, neat, strong and efficient. Great work.
You should be feeling very proud of yourself Greg, the skills, the technique and information you’ve given us throughout the build is second to none, well done my friend 🏆👍🏼😉
My LT35 van (1998 vintage) is a 'high roof' and I use it as a workshop/tool carrying facility for my vehicle projects. Was thinking of making a 'sleeper cab' but utilising the load space above a large compressor I have in the back. Would require some cutting, welding and fabrication obviously. Your videos are great for sparking the thought process and also pointing out the good and bad points I need to look out for. many thanks, Greg....(P.S. still have to fit my skylite in the rear after watching your videos earlier)
A new HSS blade with fine teeth and it will be a breeze to cut. The mastic tape is a must for levelling any ribs and finish off with sikaflex Don't forget to clean up those metal fillings after before they go rusty. Funny how cutting a big hole the roof of your expensive van can make you smile so much. Best wishes and I'm sure you'll be fine.
Thanks Roger, a slightly thicker stiffer blade and light pressure on the tool, let the blade do the work. As soon as you start trying to muscle the saw the blade bends and you get wonky cuts. Two hands to keep it steady help too. 👍🏼 I find I don’t blink at all while in the cut lol
Greg, You are a true craftsman. Well done in all aspects. Have you thought about creating a business building camper vans with what all you've learned with this one? People would probably pay a good penny for a quality innovative design and construction.
Hi David, thank you so much for your kind words. I'm giving everyone the information so I don't have to do that ;) lol Once this one is done I will be really happy to have loads of time off to enjoy it.
Easily the best van build series on youtube, ive just started my Ducato L4H2 build and I'm pretty much going to copy you 80%😁 all good I'm in Western Australia so I can get away with cheating🤣 but seriously great vids Greg, lots of inspiration👍
my goodness, how skilled are you? well, I will answer that question... you are bloody brilliant. Love your refit videos. Thank you so much. I am now gonna buy one of your t-shirts... maybe, that will allow me to get just alittle of your skill.
Very helpful video, thank you. I'm about to convert my 2003 Fiat Ducato & there is already a shelf area over the front cab so I'm already half way there, but this video gives great info on how to close it off neatly and at the same time have a useful space. Kind regards, Michael
Just watched the entire series and to say I'm very impressed by you many skills is a massive understatement ..incredible attention to detail in every way and looking forward very much to seeing it through to completion..👍👍
Absolutely first class work from conception to execution. The glossy zebrano finish looks excellent. I do think it would be useful if the manufacturer of the board developed the complementary range of screws cappings to match the finish.
Hi Norman, thanks for the compliment. I have placed the screws so that they will be under the cupboard door and adjoingin wall cupboards. so you wont actually see them under normal use.
This is so discouraging to watch! You're so experienced and have so many tools! I wanna start building out my van, but after watching your vids, very daunting
Hmmm, I'm not really, I've never done a van build before, didn't start woodwork till two years ago. Agreed some of the tools make it easier but you can do all this with just a jigsaw, drill and router. The aim of the channel was to give detailed info to help the home DIY builder not to discourage. There's great satisfaction in building it yourself in whatever form it takes. Practice makes perfect
Your love to detail and your professionalism is, as always, astonishing! Can't wait to meet you and your van at next year's Camp Quirky (I hope it'll all work out the way I want with renting a van and stuff). 👍🏼😉
Thank you very much. We are really looking forward to next years Camp Quirky, it’s going to be huge next year and I can’t wait to meet everybody and look at their new vans.
Greg Virgoe Another possible tip (depending on visibility) is to "back cut" all scribe cuts. That is, cut to the line on the face, and back from the line on the non-visible side. It's much easier to get a great fit. And if you have to take anything off, you're doing so on a thin edge.
Hi Greg a tip for the future, the spray on adhesive compared to the roll on brush on version sometimes has a lower temperature rating for adhesion. I had a problem where I used the spray on to redo the headlining of my girlfriends car, it didn't last Summer before it started to pull away. I redid it with a rolled/brushed on version of the same adhesive and I've had no problem. This might only be an issue for hotter countries but it's important to look at the temperature rating of glues when gravity and heat are an issue :)
Yeah it wasn't untill I had the failure and looked at the back of the can and it said 60-80degC and a car in the Sun here in Oz can get funkin hot. So like I said, I think it's only a problem for hot countries :)
It is generally called "Contact Adhesive" because you spray it on both surfaces, wait a few minutes then 'contact' the two pieces together. In Australia its called Kwik Grip made by Sellys. As Greg's use a spray glue with a high temp rating I hope he gets back to you with the name of the glue he used.
This is a really good video Greg. I was wondering how on Earth I was going to be able to do mine. But I’ve learnt some really valuable information. Thanks!
Hi Katy, When I first looked at it myself I did a lot of head scratching. But fixing a batten to the roof rib and the larger timber on the leading edge of the shelf make it so much stronger. Although it’s only going to hold spare bedding.
Thanks for putting in all of this work filming and editing these videos. Very helpful to all of us doing our own conversion. You are the man. Such clear and concise explanations.
The edging looks really good. Those screw caps look fantastic! I finally finished my floor. I am unsure about the insulation for my roof. Finding the stick on aluminum pin anchors in small quantities is proving rather difficult. There are steel ones available, but have poor reviews for retention. Many are rated only to 120* F, and they come loose....I'm pretty sure my van roof gets above that plenty this time of year. I did discover something that surprised me. I used the silver backed 3/4" polyiso panels to insulate the front half of the cargo area, foil side up for vapor barrier. I had a small piece of scrap lying on the metal floor, just behind the engine dog houes, and just above the trans. The floor there gets extremely hot. The scrap laying there was silver side down, and the to the touch it stays pretty much at ambient temps. The light silver film and the 3/4" poly is an amazing insulator. I'm going to frame some into that area, and put plastic over the top for a vapor barrier. Thanks again for the work you put into your videos!
Is it not 120degC? I had one that came unstuck but could not put it down to temperature, it may have been dirty?Most PIR sheets are foil on both sides, both brands I used are. Plastic is also ok to use for a vapour barrier, use the correct building membrane as some plastics are slightly permeable.
Gday Greg... from Aus. I just got my own Mercedes Sprinter and stumbled across your videos. Absolutely love them. My new bible and go to. Love your work and dedication. Goodon you! 👍
Hello Beth, very sorry, I took some footage but the video angle and sound was rubbish so I couldn't use it. I'll do a video this weekend just on "Scribing" awkward shapes because there are a few tips and tricks which will help you. Thanks for your comment and for supporting my channel
Hi Greg, fantastic videos big fan. Quick question on bulkhead you made wood plates for behind headliner great but how did you install them? Did you remove headliner completely and remount with shelf in or find a way of slotting them in place. Thanks mark
yet another great how to video Greg (If I may :) ) absolutely love that high gloss finish and the color as well. Please tell Ms. Greg she's an excellent executive assistant and I can't wait to see all her special touches on the finished van. mw
Excellent job Greg! This van build series is compulsive viewing!, in my opinion it’s up there with the New Yankee workshop, only better, because it’s real life.
Thanks for the update,,,Greg I heard you say you cut the vinyl trim a little longer,,,, that is good,,, In my earlier life I installed a lot of molding on automobiles,,, I first installed a track then put in the vinyl insert,,,We were instructed to add between 3/8 to 1/2 inch to the insert ,,, because over time the vinyl shrinks,,, It may not be as critical inside a vehicle because it does not get the sunshine directly,,,,Just FYI,,,Best Regards
Hi Greg, thanks so much for providing this absolutely essential series on the Sprinter 170 conversion, we'll be starting ours this year and will be following so many of your outstanding tutorials. One question, have you thought about providing a detailed list of all the tools and products together for the build in an upcoming video? I know that's probably a lot of work but it may get you a ton of views and likes! Anyway besides that, thank you so much again, you're truly an inspiration for many. I'm subscribed 👍. Paul
Nice video as always, I’ve been lining my van recently with the same carpet and adhesive. Take care when using the adhesive, there are some pretty alarming warnings and symbols on the can!
You are very kind, thank you. The time you do need and some patience. I've never done anything like this before so it can be done. This is a huge learning curve for me also. It helps me being very fussy and methodical in my approach
amazing job greg been watching a few videos now and you have given me some great ideas especially the trimming' love what you have created and it looks stunning' i know your now on your travels and the both of you are enjoying van life in your stunning conversion' safe travels and hopefully meet up at some point
Thanks for another great video, I'm thinking about making the overhead shelf with a bit added on to make a bed for my little ones. The extra bit would fold up during the drive. Do you think this is possible if i can reinforce the shelf for the extra weight. Thank for your time. regards Richard
Great video as usual! Quick question as I don’t think you mentioned it in video, apologies if I missed it and you did, what thickness ply did you use? Thanks
Great Video, I've been wondering what to do with that space. Thought I might leave it open for more head room while driving, but I think this idea is best for added storage etc.
Would be interested to see an outside vs inside temperature test to see how your insulation is performing as the job you did on it seems quite thorough compared to some other builds iv seen. Impressive so far 👍
Hi Darren, we did spend a lot of time to get the insulation fit and the vapour barrier complete. The walls and roof are in excess of the same insulation you would get from having 4" of loft insulation in your home. We are hoping to shoot some thermal imaging footage when we return to the Truma factory to prove how well it performs. Look out for that video soon.
Sunnycampers yes mate, take it nice and slow and let the blade do the work don’t force it. You can smooth it with a file and apply trim over so it’s not too bad. 😀
Superb Greg, well done, I just wish I could find a supplier of these board that ship to Finland. I may need to look into boat building sites/companies here as there's a lot of boats here with the thousands of lakes we have.
Hello Michael, the marine and boat building industry is a fantastic place to search for anything van related. Obviously need to be lightweight and run off 12v batteries for all electrics. Lot of similarities.
I know Peter, I lost count of the amount of times she said don’t do that you’ll scratch it 😂 I cut the bit out where she slapped my hand for putting dirty finger prints on the glossy finish. Gonna drive her OCD bananas lol
Just a thought Greg, would it be worth cutting a matching template for each piece out of plywood, you would then have a master set of your van conversion. You could then have this duplicated and market it as a kit for people wanting to do the same? Great video as usual, looking forward to the next instalment!
I would imagine that even the same model vans are very slightly different in their dimensions. I have held onto that cardboard template for now as it took a couple of hours to get right. :D
Thank's, a great and informative video as always. I didn't quite understand how you managed to position the matching piece of ply on the other side of the head liner and then align them with the batons fixed on the shelf. I'd really appreciate a clearification since we're discussing the construction of a similar shelf in our sprinter
Hello Sebastian, I pre-drilled the plywood and countersink the holes to exactly the same centres as the angled wood blocks hold the shelf up into position in the headliner and screw the screws through the headliner just enough so they are poking through a very small amount then grab the ply and reach down the sides you cannot see but you can feel when the pre-drilled holes drop over the tip of the screws, screw up tight until the two are sandwiched together. I did not put ply on the front ones just screwed them straight into the headliner. The shelf was 12mm ply and with the side and the 3x2 timber rail it is super strong.
Hi Greg, in terms of the insulation around the bulkhead is this just rock wool pushed in the gaps? Is there any risk because of there not being a vapour barrier. Worried about condensation forming and soaking the wool insulation? Thanks and love the video series.
Amazing finish on that edging strip, top tip glueing it too for sure. I'm a touch confused how you fixed the shelf to the headliner piece, how did you get the small pieces of wood it's screwed into down the other side of it without removing the whole original headlining? Especially the two at the windscreen edge? Top vid as always Sir Greg.
Hello, The two side ones are clamped to plywood on the outside and make a really solid clamping point on each side. The front ones are screwed into the bulkhead only but only to hold the join together. The rear 3x2 timber is fixed to the new bulkhead and that is screwed to a batten fixed to the roof beam. For what little is going to be stored in there it is so solid now.
Hi Greg. First off, your videos are amazing and I've followed your build process extensively! They are so informative, detailed and a joy to watch. I'm about to make a cab shelf for my Sprinter, although I cheated and bought a paper template online. One question I have though is how do you transition the angled cuts from the shallower angle on the sides of the shelf to the almost 45 degree cut on the front edge?
Hi Greg. Did you insulate the space behind the headliner? Maybe I missed it in your videos. Anyway.. was curious, if you did, what materials you used as the space is limited. Nice video again! Learned a lot from your series so far.
Yes we did but didn’t film it. It’s easy to unbolt it and remove it we used wool based insulation cover with a vapour barrier and replace the headliner. 👍🏼
Nice work think there is a market for a set of templates for van conversion. I would have installed a metal floor on your shelf with an anchor to wind shield posts and location behind seat where normal industrial divider goes. Does sprinter make a shelf as an option? If so buy one an use for template. A parts dealer has speck on oem parts spec.
You are dead right about the templates. I originally looked at flat pack van furniture but you still have to scribe it to the curves of your own van. If you are going to do that and put it together you might as well do the lot from scratch and have it how you want it.
Professional!! Beautiful work!! Does anyone know where you can order some of that lightweight furniture board in America? Thanks for taking the extra time to make all these amazing video's!!
When talking about the blades you used you mentioned you wanted to cut on the top surface so switched the blade. Maybe I'm missing something but why not just flip the piece of furniture board (and the template) and keep the upward cutting blade?
Not good I'm afraid, the van broke down and has been stuck for ages at Ford for repair. Which ment I couldn't work on it. Finally got the van back yesterday. It needed four new fuel injectors, since all the originals were corroded. How does this happen on a brand new van with just 500 miles on clock? Since I want to get the van re-classified as a MotorCaravan by the end of August, I just don't have enough time to do my planned detailed build. So as of today, I'm going to knock up a rough kitchen unit, bed and wardrobe in old ply, add some cushions and curtains and hope this is enough to get it passed. If this is sucessful, I then qualify for cheaper insurance and the vans value will have inceased enormously. I can then rip out the crap stuff and do a proper job as originally planned. There maybe a silver lining here since I can test out the layout on the old ply and make adjustments without wasting good wood. Which makes me wonder, have you got your van re-classified before you leave on your European adventure? And finally you seemed to have gained a very pretty assistant:)
Time is the one thing that you need bucket loads of doing these builds properly. That is very strange about the injectors, guessing it was all covered by your warranty? I will get our reclassified before we leave and that's the only thing that could hold us up. It's currently SORN and got no MOT while we do the build. Lots to sort out still. I heard that there was a bit of a wait to get them back as it's become so popular. Thankfully my dear mum has kindly offered to put us up for a few weeks if needed. Our house is definitely going on the 7th July no matter what so the clock is ticking loudly. Oh and yes, meet Louarnna (Lou) my beautiful partner for 17years now :D Trying my hardest to get her more involved but she's very camera shy. She does really like the festivals and is so much happier talking in person.
Sounds like some military style planning has been going on here. I'm impressed. I get nervous just catching the IOW ferry:( Tell Lou not to worry about the camera, us campers are just a bunch of harmless idiots!
Is the shelf screwed into the metal of then van, or do those wooden plates just stop it from falling any lower? Great job by the way, watching your series closely!
Nope, it's fastened to the small pieces of wood, just like at 4:40. Those 2 elements are clamping the plastic of headliner together - holding the whole plank in effect ;D Simply genius !!!
Hello David, not planning to fit any AC in the van, we are planning our route to miss the peak summer on the Med' so that when we get there later in the year it is more temperate and comfortable. I have historical annual weather data for every country in Europe and planning our route around that.
Hi Greg. Building the O/H bulkhead is a great idea, did you first of all strip out the headliner and use sound deadening and insulation? Thanks Giacomo 'Working on a Dream'
Hello Ed, the key is to have them pre drilled and countersunk first to the same centres as the wood blocks, drive the screws through the headliner so there is a small bit of the screw showing that you can drop onto, then this bit you have to do blind just by feel, located your pre drilled and countersunk holes over the screw tips then screw in. It is very tight and you do need patience, driver side was easier. Failing that it's about six screws and the headliner comes right out, that the sensible approach. Hope that helps
Many thanks for the advice Greg, I love the way that you present the videos and share your knowledge. Too many people are "precious" with their techniques these days. Always a pleasure to watch.
Another really helpful video Greg. This is next on my job list. I have all the materials and hope to start very soon. One question, the sandwich battens you have towards the windscreen, how did you get the wood plate behind the original flimsy plastic bit? I can see how you did the sides but imagining you took the whole thing out?! Many thanks, Lawrence
I only put them on the sides. The front is just screwed into the headliner. It’s really solid even with just the side ones and we only put screens as bedding up there
Hi Greg, I notice in this video you've not used reflectix to vapour barrier in the insullation over the headliner. Is this something you did afterwards? We've just ripper all ours out and are starting again as it was all wet. I was going to vapour barrier in with the over head locker over the cab. Be interested to here what you did with yours. Cheers Greg, really great series.
@@GregVirgoe thanks Greg, headliners out already just wanted to be certain we weren't wasting our time :) hope the new project is coming along, looking forward to seeing the videos when they come out :D
you are doing a really nice job, beautiful finish, very professional. I can't say my conversion is as well thought out :) I have a 2006 Sprinter and am interested in your headliner shelf. At the front did you just screw into the headliner itself, what type of screws. For the side you must have slipped that second piece of timber around the outside of the headliner and screwed outwards into it ?
All your work is first class Greg. My son is wanting to convert his Crafter Ann I keep showing him your work, spot on. Nice work shop too.
Thank you very much. I hope the videos help him to turn out a cracking van. Best wishes 😃
Your Wife is the perfect assistant, knowing when to help and more importantly when not to help. Great videos I know there 5 years old but there still solid information.
Thanks for watching 👍🏼😊
Your attention to detail is to be admired. I have improved my DIY skills just watching your content.
Thank you very much I’m glad it is helping you.
This is just outstanding. It is as close to what you would see in a coachworks, professional upfitting shop. It's also simple, neat, strong and efficient. Great work.
Very much appreciated thank you 😊
You should be feeling very proud of yourself Greg, the skills, the technique and information you’ve given us throughout the build is second to none, well done my friend 🏆👍🏼😉
That's really nice of you to say so, thank you for your regular support Marc, very much appreciated.
My LT35 van (1998 vintage) is a 'high roof' and I use it as a workshop/tool carrying facility for my vehicle projects. Was thinking of making a 'sleeper cab' but utilising the load space above a large compressor I have in the back. Would require some cutting, welding and fabrication obviously. Your videos are great for sparking the thought process and also pointing out the good and bad points I need to look out for. many thanks, Greg....(P.S. still have to fit my skylite in the rear after watching your videos earlier)
A new HSS blade with fine teeth and it will be a breeze to cut.
The mastic tape is a must for levelling any ribs and finish off with sikaflex
Don't forget to clean up those metal fillings after before they go rusty.
Funny how cutting a big hole the roof of your expensive van can make you smile so much.
Best wishes and I'm sure you'll be fine.
I'm in awe of your freehand jigsaw skills. Another helpful vid thanks......
Thanks Roger, a slightly thicker stiffer blade and light pressure on the tool, let the blade do the work. As soon as you start trying to muscle the saw the blade bends and you get wonky cuts. Two hands to keep it steady help too. 👍🏼
I find I don’t blink at all while in the cut lol
Greg,
You are a true craftsman. Well done in all aspects. Have you thought about creating a business building camper vans with what all you've learned with this one? People would probably pay a good penny for a quality innovative design and construction.
Hi David, thank you so much for your kind words.
I'm giving everyone the information so I don't have to do that ;) lol
Once this one is done I will be really happy to have loads of time off to enjoy it.
After following your videos for some time ... I declare Greg for the "ultimate master of the jigsaw". Period.
Tom111060 😀thank you
A good stiff blade is the key and don’t fight it 👍🏼
Stunning. Absolutely beautiful. And, your teaching/instruction makes me want to try this. Thanks so much!!!
Easily the best van build series on youtube, ive just started my Ducato L4H2 build and I'm pretty much going to copy you 80%😁 all good I'm in Western Australia so I can get away with cheating🤣 but seriously great vids Greg, lots of inspiration👍
It’s here to help others achieve their dream van so I’m glad you find it to be useful. Thanks for watching 😁
Wow!! I'm just planning my Sprinter conversion and I am definitely ordering this swivel feature!! Thank You Greg!!!
We love it, it really is easy to use and opens up the van to give you loads more room.
my goodness, how skilled are you? well, I will answer that question... you are bloody brilliant. Love your refit videos. Thank you so much. I am now gonna buy one of your t-shirts... maybe, that will allow me to get just alittle of your skill.
Sanjeev Chaddha I’m very grateful for your support and wish you the best with you own build 😃
Very helpful video, thank you. I'm about to convert my 2003 Fiat Ducato & there is already a shelf area over the front cab so I'm already half way there, but this video gives great info on how to close it off neatly and at the same time have a useful space. Kind regards, Michael
You are really welcome Michael, thank you for watching and good luck with your own build.
Thank you Greg
Just watched the entire series and to say I'm very impressed by you many skills is a massive understatement ..incredible attention to detail in every way and looking forward very much to seeing it through to completion..👍👍
Really appreciate your kind words Dave, It's nice to know that comes across in the videos.
Hope you continue to enjoy them. Thank you
Absolutely first class work from conception to execution. The glossy zebrano finish looks excellent. I do think it would be useful if the manufacturer of the board developed the complementary range of screws cappings to match the finish.
Hi Norman, thanks for the compliment.
I have placed the screws so that they will be under the cupboard door and adjoingin wall cupboards. so you wont actually see them under normal use.
This is so discouraging to watch! You're so experienced and have so many tools! I wanna start building out my van, but after watching your vids, very daunting
Hmmm, I'm not really, I've never done a van build before, didn't start woodwork till two years ago.
Agreed some of the tools make it easier but you can do all this with just a jigsaw, drill and router.
The aim of the channel was to give detailed info to help the home DIY builder not to discourage.
There's great satisfaction in building it yourself in whatever form it takes. Practice makes perfect
Your love to detail and your professionalism is, as always, astonishing! Can't wait to meet you and your van at next year's Camp Quirky (I hope it'll all work out the way I want with renting a van and stuff). 👍🏼😉
Thank you very much. We are really looking forward to next years Camp Quirky, it’s going to be huge next year and I can’t wait to meet everybody and look at their new vans.
Nice job again , I ran a workshop for a couple of years and we used a small rubber mallet to tap the edging in. PS looks very professional.
Awesome. Keen to see what you have coming up for tricky stuff like the overhead cabinets etc.
Hello, you can see my high level cupboards design in this video ua-cam.com/video/SoytP-XmtfI/v-deo.html
Greg Virgoe. like that vid too. Really outlines the function of CAD. More interested in your ideas of mounting it in a vehicle.
Nicely done Greg, got a great fit there! Handy tip on the jigsaw blades too.
I was really pleased, I did not have to trim or sand anything the card template worked a dream. That’s the most complicated cuts done now.
Greg Virgoe A great example of the "Measure twice. Cut once.' rule.
When in doubt, template it out!
Greg Virgoe Another possible tip (depending on visibility) is to "back cut" all scribe cuts. That is, cut to the line on the face, and back from the line on the non-visible side. It's much easier to get a great fit. And if you have to take anything off, you're doing so on a thin edge.
Hi Greg a tip for the future, the spray on adhesive compared to the roll on brush on version sometimes has a lower temperature rating for adhesion. I had a problem where I used the spray on to redo the headlining of my girlfriends car, it didn't last Summer before it started to pull away. I redid it with a rolled/brushed on version of the same adhesive and I've had no problem. This might only be an issue for hotter countries but it's important to look at the temperature rating of glues when gravity and heat are an issue :)
Hi Karl, this one is rated to 120degC I would have thought that would be ok 👌🏼 it does stick like s?&@ to a blanket.
Greg Virgoe I concur!
Yeah it wasn't untill I had the failure and looked at the back of the can and it said 60-80degC and a car in the Sun here in Oz can get funkin hot. So like I said, I think it's only a problem for hot countries :)
Where did you get the adhesive from mate ? And what's the name of it please. I want to re do the headlining on my car
It is generally called "Contact Adhesive" because you spray it on both surfaces, wait a few minutes then 'contact' the two pieces together. In Australia its called Kwik Grip made by Sellys. As Greg's use a spray glue with a high temp rating I hope he gets back to you with the name of the glue he used.
This is a really good video Greg. I was wondering how on Earth I was going to be able to do mine. But I’ve learnt some really valuable information. Thanks!
Hi Katy, When I first looked at it myself I did a lot of head scratching. But fixing a batten to the roof rib and the larger timber on the leading edge of the shelf make it so much stronger. Although it’s only going to hold spare bedding.
Thanks for putting in all of this work filming and editing these videos. Very helpful to all of us doing our own conversion. You are the man. Such clear and concise explanations.
It's really nice to know they are appreciated, Thank you
The edging looks really good. Those screw caps look fantastic!
I finally finished my floor. I am unsure about the insulation for my roof. Finding the stick on aluminum pin anchors in small quantities is proving rather difficult. There are steel ones available, but have poor reviews for retention. Many are rated only to 120* F, and they come loose....I'm pretty sure my van roof gets above that plenty this time of year.
I did discover something that surprised me. I used the silver backed 3/4" polyiso panels to insulate the front half of the cargo area, foil side up for vapor barrier.
I had a small piece of scrap lying on the metal floor, just behind the engine dog houes, and just above the trans.
The floor there gets extremely hot.
The scrap laying there was silver side down, and the to the touch it stays pretty much at ambient temps. The light silver film and the 3/4" poly is an amazing insulator. I'm going to frame some into that area, and put plastic over the top for a vapor barrier.
Thanks again for the work you put into your videos!
Is it not 120degC? I had one that came unstuck but could not put it down to temperature, it may have been dirty?Most PIR sheets are foil on both sides, both brands I used are.
Plastic is also ok to use for a vapour barrier, use the correct building membrane as some plastics are slightly permeable.
Really enjoyed your videos, many thanks, very therapeutic and calming. Always wanted a motor home whether converted or factory design
Gday Greg... from Aus.
I just got my own Mercedes Sprinter and stumbled across your videos. Absolutely love them.
My new bible and go to.
Love your work and dedication.
Goodon you! 👍
It looks AMAZING. I wish you'd been a little more detailed about how you made the initial cardboard guide for the bottom shelf of the cupboard.
Hello Beth, very sorry, I took some footage but the video angle and sound was rubbish so I couldn't use it.
I'll do a video this weekend just on "Scribing" awkward shapes because there are a few tips and tricks which will help you.
Thanks for your comment and for supporting my channel
Greg Virgoe thank you. Much appreciated.
Hi Greg, fantastic videos big fan. Quick question on bulkhead you made wood plates for behind headliner great but how did you install them? Did you remove headliner completely and remount with shelf in or find a way of slotting them in place. Thanks mark
Wondering the same thing. I don’t get it, did he just screw right into the headliner and that’s how the shelf is supporting weight?
Same question
Anyone ever figure it out?
Thanks for another great video. Your care for details is simply extraordinary. Thanks for sharing your great work.
Thank you for your continued support and great feedback
yet another great how to video Greg (If I may :) ) absolutely love that high gloss finish and the color as well. Please tell Ms. Greg she's an excellent executive assistant and I can't wait to see all her special touches on the finished van. mw
Excellent job Greg!
This van build series is compulsive viewing!, in my opinion it’s up there with the New Yankee workshop, only better, because it’s real life.
Thanks for the update,,,Greg I heard you say you cut the vinyl trim a little longer,,,, that is good,,, In my earlier life I installed a lot of molding on automobiles,,, I first installed a track then put in the vinyl insert,,,We were instructed to add between 3/8 to 1/2 inch to the insert ,,, because over time the vinyl shrinks,,, It may not be as critical inside a vehicle because it does not get the sunshine directly,,,,Just FYI,,,Best Regards
Hi Greg, thanks so much for providing this absolutely essential series on the Sprinter 170 conversion, we'll be starting ours this year and will be following so many of your outstanding tutorials. One question, have you thought about providing a detailed list of all the tools and products together for the build in an upcoming video? I know that's probably a lot of work but it may get you a ton of views and likes! Anyway besides that, thank you so much again, you're truly an inspiration for many. I'm subscribed 👍. Paul
Well done Greg can’t wait to see your travels
It’s going to be great to have you along with us. Very excited now it’s getting closer
Nice video as always, I’ve been lining my van recently with the same carpet and adhesive. Take care when using the adhesive, there are some pretty alarming warnings and symbols on the can!
Yes, thank you. Always use in a very well ventilated area.
Thanks very much for sharing your knowledge and skills
Excellent stuff. This Van is the van I would make (if I had the skills, time and patience)
You are very kind, thank you.
The time you do need and some patience.
I've never done anything like this before so it can be done.
This is a huge learning curve for me also.
It helps me being very fussy and methodical in my approach
amazing job greg been watching a few videos now and you have given me some great ideas especially the trimming' love what you have created and it looks stunning' i know your now on your travels and the both of you are enjoying van life in your stunning conversion' safe travels and hopefully meet up at some point
Great place to add a storage.
Thanks for another great video, I'm thinking about making the overhead shelf with a bit added on to make a bed for my little ones. The extra bit would fold up during the drive. Do you think this is possible if i can reinforce the shelf for the extra weight. Thank for your time.
regards
Richard
Great video as usual! Quick question as I don’t think you mentioned it in video, apologies if I missed it and you did, what thickness ply did you use? Thanks
Just beautiful. I am going to use that furniture board in my build.
Great Video, I've been wondering what to do with that space. Thought I might leave it open for more head room while driving, but I think this idea is best for added storage etc.
There is a massive headroom even with the shelf installed I'm nearly 6' and nowhere near my head at all.
Would be interested to see an outside vs inside temperature test to see how your insulation is performing as the job you did on it seems quite thorough compared to some other builds iv seen. Impressive so far 👍
Hi Darren, we did spend a lot of time to get the insulation fit and the vapour barrier complete. The walls and roof are in excess of the same insulation you would get from having 4" of loft insulation in your home. We are hoping to shoot some thermal imaging footage when we return to the Truma factory to prove how well it performs. Look out for that video soon.
Yet another great tutorial.
A great addition to what will be a fantastic van fit out.
Well done.
most helpfull videos ever!!!! Thank you evr so much for all the tips.
Great vid as always - did u mention what thickness ply the shelf is? Thanks as always!
I'm pretty sure it was a bit of 12mm left-over from the flooring
amazing greg, but still I'm confused how to scribe properly so it fits exactly the van, its the one thing I see nobody explaining properly
Watch my furniture video I explain it there. Also the kitchen counter top I explain it there too
@@GregVirgoe thanks Greg must have missed that video
Brilliant job Greg.
Many thanks Sandy
fine job sir. good luck with all your plans
Many thanks David
Wow! You're cutting the internal corners on the board freehand with a jigsaw. I may have to make a jig for this. Thanks Greg ✔️😊
Sunnycampers yes mate, take it nice and slow and let the blade do the work don’t force it. You can smooth it with a file and apply trim over so it’s not too bad. 😀
Nice clean workmanship, very helpful, looks great
Excellent advice Thanks, the Lawn looks top also
Superb Greg, well done, I just wish I could find a supplier of these board that ship to Finland. I may need to look into boat building sites/companies here as there's a lot of boats here with the thousands of lakes we have.
Hello Michael, the marine and boat building industry is a fantastic place to search for anything van related. Obviously need to be lightweight and run off 12v batteries for all electrics. Lot of similarities.
Nice work so far Greg, I see the boss is trying to muscle in on the video’s😂
I know Peter, I lost count of the amount of times she said don’t do that you’ll scratch it 😂 I cut the bit out where she slapped my hand for putting dirty finger prints on the glossy finish. Gonna drive her OCD bananas lol
this man is real professional
Just a thought Greg, would it be worth cutting a matching template for each piece out of plywood, you would then have a master set of your van conversion. You could then have this duplicated and market it as a kit for people wanting to do the same? Great video as usual, looking forward to the next instalment!
I would imagine that even the same model vans are very slightly different in their dimensions.
I have held onto that cardboard template for now as it took a couple of hours to get right. :D
Looks fantastic! Enjoying your quality videos.
Thank you very much Joseph
Wow, you grow a stubble quickly!!!!! from yesterday's vid to today.... what a growth...lol
Yeah I know, sometimes have to shave twice a day ;) lol
Cheers Greg, another great tutorial.
Thank you David
nice one Greg, a great use of the space.
You have to be creative to make the most of it.
Scratching my head to think of garage storage ideas now.
Hi Greg. cargo nets maybe, or adjustable height shelving. All depends on what your wanting to store.
Outstanding attention to detail....👏👏👏
Sorry about binge watching all your vids and endless likes mate, apologies but enjoying it too much not to show the little appreciation I can
Please do not apologise, I'm glad to see you are enjoying the videos and thanks for watching
I will base my project on your teachings! (Vou basear meu projeto nos teus ensinamentos!)
I'm glad that they are useful to you.
just started watching your videos ..Gold !!!
Thank's, a great and informative video as always. I didn't quite understand how you managed to position the matching piece of ply on the other side of the head liner and then align them with the batons fixed on the shelf. I'd really appreciate a clearification since we're discussing the construction of a similar shelf in our sprinter
Hello Sebastian,
I pre-drilled the plywood and countersink the holes to exactly the same centres as the angled wood blocks
hold the shelf up into position in the headliner and screw the screws through the headliner just enough so they are poking through a very small amount then grab the ply and reach down the sides you cannot see but you can feel when the pre-drilled holes drop over the tip of the screws, screw up tight until the two are sandwiched together. I did not put ply on the front ones just screwed them straight into the headliner. The shelf was 12mm ply and with the side and the 3x2 timber rail it is super strong.
+Greg Virgoe I really appreciate you taking the time to answer. Your method makes sense and we'll probably do it the same way
Hi Greg, in terms of the insulation around the bulkhead is this just rock wool pushed in the gaps? Is there any risk because of there not being a vapour barrier. Worried about condensation forming and soaking the wool insulation? Thanks and love the video series.
Hi, nice job, looks lovely 👍.
Thank you 😊
Nice neat job Sir.
I’ve been taking some tips from your very clean and tidy videos 👍🏼 Thanks guys lol
Looks very neat!
Thank you
Beautiful!
Absolutely, thank you. we love the shiny finish. :D
Amazing finish on that edging strip, top tip glueing it too for sure. I'm a touch confused how you fixed the shelf to the headliner piece, how did you get the small pieces of wood it's screwed into down the other side of it without removing the whole original headlining? Especially the two at the windscreen edge?
Top vid as always Sir Greg.
Hello, The two side ones are clamped to plywood on the outside and make a really solid clamping point on each side.
The front ones are screwed into the bulkhead only but only to hold the join together.
The rear 3x2 timber is fixed to the new bulkhead and that is screwed to a batten fixed to the roof beam.
For what little is going to be stored in there it is so solid now.
@@GregVirgoe hi, not clear on the fixing. Did you sandwich the liner between the ply and battens?
Great video Greg helps alot
Hi Greg. First off, your videos are amazing and I've followed your build process extensively! They are so informative, detailed and a joy to watch.
I'm about to make a cab shelf for my Sprinter, although I cheated and bought a paper template online. One question I have though is how do you transition the angled cuts from the shallower angle on the sides of the shelf to the almost 45 degree cut on the front edge?
Make them all at the steeper angle. You will not see the slope above from the underside, just the leading cut edge. 👍🏼😃
Nice work looks very professional.
Thanks Rob, we are really thrilled with the finish.
Hi Greg. Did you insulate the space behind the headliner? Maybe I missed it in your videos. Anyway.. was curious, if you did, what materials you used as the space is limited. Nice video again! Learned a lot from your series so far.
Yes we did but didn’t film it. It’s easy to unbolt it and remove it we used wool based insulation cover with a vapour barrier and replace the headliner. 👍🏼
Hi Greg, can you tell me how much furniture board you used in total for the build please? The videos are top class! Many thanks.
I used 7 sheets in total including closing in the garage at the back
Nice work think there is a market for a set of templates for van conversion. I would have installed a metal floor on your shelf with an anchor to wind shield posts and location behind seat where normal industrial divider goes. Does sprinter make a shelf as an option? If so buy one an use for template. A parts dealer has speck on oem parts spec.
You are dead right about the templates.
I originally looked at flat pack van furniture but you still have to scribe it to the curves of your own van.
If you are going to do that and put it together you might as well do the lot from scratch and have it how you want it.
What size ply did you use on the base of the bulkhead please
Professional job!
Professional!! Beautiful work!! Does anyone know where you can order some of that lightweight furniture board in America? Thanks for taking the extra time to make all these amazing video's!!
Looks good even without a door.
Another great informative video. Big thumbs up 👍
When talking about the blades you used you mentioned you wanted to cut on the top surface so switched the blade. Maybe I'm missing something but why not just flip the piece of furniture board (and the template) and keep the upward cutting blade?
You can do that if you want. 😊
Proper job Greg. Even your noggins look wonderful:)
Thank you mate, how are you getting on with the transit build?
Not good I'm afraid, the van broke down and has been stuck for ages at Ford for repair. Which ment I couldn't work on it. Finally got the van back yesterday. It needed four new fuel injectors, since all the originals were corroded. How does this happen on a brand new van with just 500 miles on clock?
Since I want to get the van re-classified as a MotorCaravan by the end of August, I just don't have enough time to do my planned detailed build. So as of today, I'm going to knock up a rough kitchen unit, bed and wardrobe in old ply, add some cushions and curtains and hope this is enough to get it passed.
If this is sucessful, I then qualify for cheaper insurance and the vans value will have inceased enormously. I can then rip out the crap stuff and do a proper job as originally planned. There maybe a silver lining here since I can test out the layout on the old ply and make adjustments without wasting good wood.
Which makes me wonder, have you got your van re-classified before you leave on your European adventure?
And finally you seemed to have gained a very pretty assistant:)
Time is the one thing that you need bucket loads of doing these builds properly.
That is very strange about the injectors, guessing it was all covered by your warranty?
I will get our reclassified before we leave and that's the only thing that could hold us up.
It's currently SORN and got no MOT while we do the build. Lots to sort out still.
I heard that there was a bit of a wait to get them back as it's become so popular.
Thankfully my dear mum has kindly offered to put us up for a few weeks if needed.
Our house is definitely going on the 7th July no matter what so the clock is ticking loudly.
Oh and yes, meet Louarnna (Lou) my beautiful partner for 17years now :D
Trying my hardest to get her more involved but she's very camera shy.
She does really like the festivals and is so much happier talking in person.
Sounds like some military style planning has been going on here. I'm impressed. I get nervous just catching the IOW ferry:( Tell Lou not to worry about the camera, us campers are just a bunch of harmless idiots!
Is the shelf screwed into the metal of then van, or do those wooden plates just stop it from falling any lower? Great job by the way, watching your series closely!
Chris B... thinking the same thing? Is there a rib to fix to? Great vids btw. Doing my own conversion and these videos are great.
Nope, it's fastened to the small pieces of wood, just like at 4:40. Those 2 elements are clamping the plastic of headliner together - holding the whole plank in effect ;D Simply genius !!!
I will third that question. I was checking my bulk head. I'm assuming you didn't just screw to the headliner and backing.
But how do you get the small piece of wood on the other side of the plastic?
Oh and awesome work as always mate 🙏🏼
I'm starting to think he maybe removed the headliner and fitted the shelf before refitting?
es asombroso lo que lograste, quiero hacer algo muy parecido. exito con tu proyecto!
racias por su amable comentario y mis mejores deseos para su propio proyecto de conversión de furgoneta.
I use laminate flooring blades, no tearout on either side of the board!
Hi Tim, the ones I got from Rawlplug left a really clean finish but I’ll look up the laminate blades. Cheers
Hi Greg, great project and great updates. Can I just enquire as you are now planning to go full timing in Europe are you going to install Air Con.
Hello David, not planning to fit any AC in the van, we are planning our route to miss the peak summer on the Med' so that when we get there later in the year it is more temperate and comfortable. I have historical annual weather data for every country in Europe and planning our route around that.
Hi Greg. Building the O/H bulkhead is a great idea, did you first of all strip out the headliner and use sound deadening and insulation?
Thanks
Giacomo 'Working on a Dream'
Sound deadening was already installed by the manufacturer and I filled the void with Earthwool insulation. Thanks
Loved the video Greg as always, but I would love to know how you got the packing pieces behind the headlining.... or is it just time and patience.
Hello Ed, the key is to have them pre drilled and countersunk first to the same centres as the wood blocks, drive the screws through the headliner so there is a small bit of the screw showing that you can drop onto, then this bit you have to do blind just by feel, located your pre drilled and countersunk holes over the screw tips then screw in. It is very tight and you do need patience, driver side was easier. Failing that it's about six screws and the headliner comes right out, that the sensible approach. Hope that helps
Many thanks for the advice Greg, I love the way that you present the videos and share your knowledge. Too many people are "precious" with their techniques these days. Always a pleasure to watch.
Another really helpful video Greg. This is next on my job list. I have all the materials and hope to start very soon. One question, the sandwich battens you have towards the windscreen, how did you get the wood plate behind the original flimsy plastic bit? I can see how you did the sides but imagining you took the whole thing out?! Many thanks, Lawrence
I only put them on the sides. The front is just screwed into the headliner. It’s really solid even with just the side ones and we only put screens as bedding up there
@@GregVirgoe thanks that’s good to know as really didn’t fancy taking the whole thing out! We’ll likely use it for the same!
Full of useful information as usual. Thanks!
Looks very nice! 😎
Hi Greg, I notice in this video you've not used reflectix to vapour barrier in the insullation over the headliner. Is this something you did afterwards? We've just ripper all ours out and are starting again as it was all wet. I was going to vapour barrier in with the over head locker over the cab. Be interested to here what you did with yours. Cheers Greg, really great series.
Yes you do need to vapour barrier over the insulation to stop condensation. It mean the headliner has to come out 😬
@@GregVirgoe thanks Greg, headliners out already just wanted to be certain we weren't wasting our time :) hope the new project is coming along, looking forward to seeing the videos when they come out :D
you are doing a really nice job, beautiful finish, very professional. I can't say my conversion is as well thought out :) I have a 2006 Sprinter and am interested in your headliner shelf. At the front did you just screw into the headliner itself, what type of screws. For the side you must have slipped that second piece of timber around the outside of the headliner and screwed outwards into it ?
Beautiful Job !
At 5:10 - did you screw the board to the van wall directly?
Great job!
Thank you Glenn