Snail trail

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Snail trail

Postby NUG637 » Sun Nov 17, 2013 3:06 am

Ok just to get you up to speed....

The story begins with me and my g/f have always wanted to travel australia by road. talked about doing it in a tin top kombi.... but voted against it for not enough room for what could potentially be 1 year+ long trip. Off and on our excitement would grow but i had to finish my apprenticeship and finish my oval resto befor i wanted to go anywhere.... 5 years later and i now work for myself and am enjoying crusing the oval and we have commited to "making it happen"

so a mate down south found this bus in a paddock..... once in its lifetime it has had a big whack in both sides but otherwise solid as....

Image

Image

Image

Image

Image

my brother bought it a whileback with intentions of doing a quick job on it and flipping it.... but time and interest werent on his side so we bought it off him with the plan of turning it into our "home" for a while....

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:20 am

with not being to keen on a tintop idea i bought a heap of camper stuff including a pop top... but then it happend...... i made the mistake of showing my partner how cool the autovilla's were (south african kombi motorhomes) and stupidly saying "that wouldnt be to hard to make" with her reply of "we should make ours into one".... we could travel so much more comfortably ](*,) . This was around the same time the cool flow had just be revealed.... and we were blown away with that thing. and from that day.... we have had a plans set in concrete....

next year there is a show on about 800Km south from were we live and is only held every 2 years because of the effort that goes into australias biggest vw show week Known and "Valla". This is our deadline to leave.... as of christmas I'm not taking on anymore work and ill be going full time on building this snail. we plan on attending the show and then kicking off our travells from there \:D/ lets hope it comes together aswelll as i hope :-k

the following week i had the engineer around and he gave me the ok to start cutting away what wasnt needed....


Image

Image

Image

Image

got started on the opposite side befor i packed up and after i cut the corner off i noticed a little black box tucked up in the battery tray area....

Image

Image

Image

Spare keys 8) 8)

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:23 am

50mm back from the strengthener on the front cab....

Image

Image

a bit of string to hold it in place while i cut so i doesn't jamb up on the 9" and to lower it down on my own.... might put the tool boxes on the back and drive it to work on monday

Image

Image

Image

Image

Image

off to the drawing board!

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:25 am

it is a hell of alot harder to create a better shape then the autovilla's and the cool flo

Image

Image

ive had enough measurements to make a shopping list of alloy... its just the design im had trouble altering now....

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:30 am

while brainstorming the frame i had a few little spots to clean up

Image

Image

Image



Image

Image


Image

Image



Image

Image

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:32 am

Got the floor ready to be extended.... placed an order for my first lot of steel and alloy and bought some repro belly pans to keep the engineer happy.. Also got a teflon lined mig handle/torch for alloy wire and have a bottle of argon on the way. 8)

Image

Floor sections/returns welded together and beaten over to be extended...

Image

Image

Image

Image

Image

Image



Wheel arches cut.... stretched open more and ready to be extended out to the snail walls....

Image

Image

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:36 am

My steel and alloy order arrived, mind you, alot of how im approaching it is making it up on the spot..... i had a brief idea of where i wanted to attach the floor structure to the car and although my first idea didnt work exactly how i thought it would.... it has all panned out beautiful with a few adjustments in the mock up 8)

Image

my datum point is my existing floor, i have set the heights of my front 2 sprockets 50mm below floor height to allow a full length of 50x25 to run ontop of them and create a bearer for my walls. The third sprocket at the back is set to floor height to allow the bearer to butt into it and be welded, Im using a string line to determin heights and width and so far its looking ace!!

The front sprocket i had to pie cut and bend about 2 degrees upwards to be 50mm below floor height. I also checked it out over the solid chassis rail and notched it in so i sits hard againt my jacking point which is tied in from one side to the other giving me plenty of surface to weld to and support my outer alloy frame.... in the pictures below the redline is where i plan to weld allong the jacking point...

Image

Image

Image

Image

Image

3mm wall steel is strong as shit!

Image

Image

Image

the straight edge in the below picture is my floor height and with the sprockets 50mm below it, it allows to me run a bearer ontop like im showing with an off cut...

Image

The bus is currently 1640mm wide measured at the floor... im pushing it out to 2100mm to allow for 50mm of walls (2x20mm studs + 2x5mm inside wall cladding = 50mm) giving 2050mm for me to lay across ways above the cabin

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:37 am

It's really not as easy as you think welding upside down... The first sprocket didn't look to pretty but nothing a grinder won't clean up.... The welds turn to shit once it get close to that lap of the sheet metal in the jacking points... They must have sandwiches some sort of sealer in there cus when it gets hot it pours out and ruins that section of weld....

Image

Image

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:38 am

finished off the first stage of the floor structure....

Image

Image

Image

Image

in the pics it looks like i could of done that in 5 minutes but checking heights and widths and notching steel over chassis etc really burns up time

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:40 am

the rear most mount would easily hold my weight but was the weakest of the lot so i thought this would help strengthen it up while making it easier to frame over/on

Image

Image

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:42 am

Spent 4 hours just sitting there looking at how I was gonna attack the next stage after some violent kicking, throwing tools and calling it multiple obscene words I went to bed fuming... Got to work the next morning and my day just dragged on because of how keen I was to get back in the shed....

The plan was to cut down the roof to make some room for mattresses and keep the overall height Down with as much room over our bed as possible as shana (g/f) is claustrophobic... We are trying to work with about 700mm over the mattress.... The thing that was picking my brain was how to mark a level line on a curved surface..... Quick trip to the hardware made life so much easier....

Leveled the floor of the bus up on stands to make sure it level both ways and then started following the red lines with a pen.

Image

Image

ordered a sheet of 1.6mm steel to weld back into the roof and make the base for our bed (in theory) as mentioned earlier... Making it up as I go...

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:45 am

And then we had a sun roof... 8)

Image

Image

Image

Less to body work now....

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:48 am

After cutting the roof, i got a better look inside and I decided to lay the beam against the old roofing bow which lines up with the body line behind the front doors which is where I have stopped the floor! Perfect! Befor welding the beam tho I welded up all the seams I cut through as I imagen it would tie it all together and make stronger..


Image

Image


Image

The bed base/floor will lay straight on this and be welded around the roof line... Seems like a lot of work to only gain 100mm but it all counts if we can keep the overal height down

I'm getting better at this welded gig... Not all of them look like this but it's getting more consistent


Image

Tacked on a quick brace to stop the sheet from sagging and sat it ontop to get abit it of a visual and to mark where I had to clean up to weld..

Image

Image

Image

Image

The overhang over the front will be trimmed abit... How much isn't known just yet cus I have to account for a tight roll and still fit in a double matress... But I would like it to line up with the base of the windscreen.

We are hoping the tension of the sheet once fully welded to the existing roof and attached to the wall framing will not require anymore framing to hold a matress and the weight of 2 bodies and not "drum" while driving... If this is not the case and needs more structure I will frame it with alloy box and ply over the top to support us and stop it from drumming etc...

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:50 am

The roof done.... Warped like fuck but should be pretty well hidden anyways

Image


Image

Image

With the offcut of the roof sheet I thought I would extend the passenger floor with it. As the passenger side is gonna cop the most traffic (door) It seemed like a good idea to use the thicker sheet (1.6mm) here and then extend the rest out of 1mm or thinner...

Added a few flooring supports at either end on both sides but put an extra one in where the traffic of the door should be.

Image

Image

User avatar
NUG637
Posts: 366
Joined: Thu Jan 10, 2013 2:46 am
Location: Australia

Postby NUG637 » Sun Nov 17, 2013 3:52 am

Bent the tubs up by hand and formed a few bends with the hammer.... so much room for big tread back there now

Image

Image

Image

left abit of over hang to allow for me to beat a right angle lip to pop rivet through to the outter wall/skin. This laser level has really come in handy... mad an easy job of getting the line i have to beat along 8)

Image

a heap of room on this side now for 2 house batteries i would think and the starter battery on the other side

Image


Return to “Baywindow Central”

Who is online

Users browsing this forum: No registered users and 2 guests