Flooring

Having previously sourced the 12mm ply floor next it’s time to get/fit the covering.  I did quite a bit of Googling and decided on using some Altro Xpresslay which I purchased from Contract Flooring.  This particular version of Altro doesn’t need gluing down, just using the double-sided tape they provided.  This is the colour I went for.

I used the plywood floor as the template (remembering to have both the floor & covering inverted!).

I used a thin marker to draw around the ply floor.

Then it was just a case of carefully cutting with a pair of scissors.

The finished product layed out.

More pondering about LPG

So, I’ve had a look at my LPG tank and the first problem is that the exit valve hasn’t been inserted enough.
When I install the cover, you can see that the outlet doesn’t line up with the hole and worse still I can’t get the cover on since the tap is too proud!
Also I think I need to return some items (since I ordered the incorrect bits).  For example, there’s no easy way to use the fill hose without it routing over the van exhaust pipe due to the radius restrictions.

LPG tank & bits delivery

Caveat: The first thing to say is that I’m not “gas trained/certified” in any way, so my musings on here are just that, nothing else.  Whilst I’m doing my install myself I already have spoken to a certified individual who knows what I’m planning to do and has agreed to test/certify my installation and provide me (and thus my insurance company) with the appropriate documentation.

So, I’ve recently received my order from Tinley Tech.  I decided to not buy the VW specific kit since it didn’t have exactly the bits I wanted (and it didn’t seem to be any cheaper than the individual parts, by my reckoning anyway).

This is the tank I bought (200mm x 585mm, 16L), shown with what’s fitted as shipped.
A close-up of the holes.  I’ve noticed the lefthand valve isn’t fitted quite square (but I haven’t tried to adjust it yet).

This is the gas tight cover which comes with the tank (not sure if I’m missing a rubber part/grommet to make all the holes gas tight though?

This is the box shown open.
Here are some more bits included with the tank and also a 90 degrees adaptor (which I think is for the filler connection?).  Note the the level/gauge isn’t included, see next comment.
I also ordered these two parts to enable me to see the LPG level from inside the van, the Livello Level Indicator and also the 4-Hole Level Sender (this comes with the gauge in the previous picture).  The cable length is pretty short, so I will need to extend it.
Here are the Tank Brackets, ordered separately.  I ordered 3 since I read that the rules specify you must have 3 if you’re suspending the tank on the mounts (although TBH, I’m not sure if I’ll be able to actually fit 3 on such a small tank?  I assume the rubber bands are to protect the tank.
This is the JIC Fill Hose – Straight, ordered separately, TBH I guessed that I’d need the straight 1.5 meter version (time will tell if I’m right!).
These are the JIC Pipe Clips for the hose (again ordered separately).

These are the bits I bought for the fill point, 3 parts.  The bracket, the UK bayonet filler (straight) and the Square filler cap.

 Assembled view.
This is the 3-way manifold I bought, for connection to the hob, Propex heater and BBQ point.
I’m not at all sure I’ve purchased the correct regulator (i.e. with the right connections on it!), since I wasn’t sure how/where I would be fitting it when I ordered it.
Lastly, something I definitely bought in error, a boot I thought would cover the back of the fill fitting but it’s way too big for me.

So the only things I’m missing (I think) are some pipe and the BBQ connection, oh and also some underbody stone chip spray which I’ve heard is recommended to protect the tank.

LPG Tank size / location

So back on measuring up for an LPG tank again.  I don’t think either of the two tanks from Gas It which I’d been considering will actually fit after making a pair of cardboard mock-ups.
Now I’m looking at this one from Tinley Tech (the 200mm x 585mm, 16L version).
I’ve modified my cardboard “tank” down to 585mm and it seems to fit very well.
And no clashing with the Kiravans Rib rear seat fitting crossmember.

This is my attempt at dragging my upturned iPhone on a mat under my van whilst taking a panoramic photo!  The top is the rear of the van.

 A close-up of the “tank” and the Rib seat cross member.

A closer shot.

And from the NSR of the van.

And again.

Fitting the Rib rear seat (again)

So, checking the fit of the Rib fitting kit under the van.  Based on the temporary spacers I had to slot, in it’s about 6-7mm too short.
 So I’ve fashioned a couple of spacers out for 3mm steel (which I’m going to rust proof before fitting).
 With the fitting kit placed in the recommended location the rear cushion is very squashed-up when in “bed-mode” so I wondered if I could mount the seat slightly forward?  However I checked the position of the three holes I’d need to drill to fix the front frame of the seat and they’d be inaccessible from under the van.
I drilled an offset pilot hole through the floor (from inside to out) near the front mounting holes to have an accurate point to measure from under the van.  After checking, I think I can position the seat very slightly further forward than stated in the instructions.  Whilst the seat is touching the side of the van, it isn’t overly squashed.
However I’ve found another issue/query, this time, in relation to the left/right position of the centre front mounting hole (in the centre of this picture).
 The hole in question is on the centre, lefthand side of this photo.
Based on the measurements from the reference hole I’d drilled the centre/front hole will exit under the boxed-in section for the NSR suspension arm!  So not sure how I’d get a bolt in there. Also not sure whether this issue is specific to a LWB?
[Update 20170507]
So back under the van, this time to measure where I think the bolts will need to come through from inside (yellow dots are my best estimates).
NSR bolt.

NSF bolt (closest to NS sliding door).

OSR (the one which the instructions say needs the long bolt since it goes through the box section).

OSF, right above the exhaust pipe.

Middle/front, the problem one (doesn’t go where the yellow dot is but inside the box section as far as I can tell).

 

 

Looking for space

My plan is to install an underbody LPG tank so time to look for a suitable space for it.  I originally thought that the sensible location (between the rear wheels) would clash with the location of the Rib mounting bar but I’m glad to say that this is not the case.  The Rib mounting actually fits above the front edge of the spare wheel so there’s a potential space in front of that as show in these photos.

I’m looking to get a tank from Gas IT, the one shown here.  It’s 200mm diameter and 717mm long.  I’ve heard that this is the one typically used with a VW T5 but not 100% sure it will fit.  I’ve measured the space and there seems to be enough space front-to-back (approx. 200mm) and also enough height (approx. 250mm), down to the anti-roll bar. However whilst the width is approx. 750mm an angle on the exhaust intrudes into the space reducing it to approx. 660mm.  So perhaps more thought required?

[Update 20170505]

Have spoken to Gas It again (very friendly/helpful guys) and think I need to get back under my van and have another measure.

If the EASYFIT – 200mm x 20 ltr one is too long then I reckon I might be able to fit the 230 x 23 ltr one in.

The measurements are as follows (for the main body/part of the tank):

  • 200 mm x 20 litre : 200mm diameter x 717mm long
  • 230 mm x 23 litre : 230mm diameter x 630mm long

Day 3 from underneath…

More fun under the van.  Under the van I tie-wrapped the cable to the fixings for the fuel pipes.
This is the cable poking up under the passenger seat.  I needed a bit of washing up liquid to get the cable through the existing hole.
 More exciting “under van” shots!
 Grommet to the right is the one under the passenger seat.
 Cable continuing to the rear of the van.
 13-pin socket connected.  Don’t forget to fit the grommet/cover first!

Socket fitted to the van.

I chose to use the side entry option since I thought the rear entry one would foul with the spare wheel.

More cable routing, this time from the rear wheels back.

Routing towards the rear bumper.

Right all done with this for today.  Only have the connections to make, saving that for another day!