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Had the same problems around the wheel arches and above the engine compartment where the windscreen wiper motor is fixed, I welded in a new shelf and coated with fibreglass to prevent rain water running through into the cab and under the rubber mat as I suspect this is what caused the extensive rot to the floor.

By the way, what is the issue with the cab heater hose from the blower to the heater matrix?? Have been to see a handful of vans at breakers yards and none have them fitted!!
                                                                             
I noticed that the roof leaked when it rained so purchased a tarpaulin to cover the whole van while I continued to work inside, I figured on leaving the roof until the interior was finished in the hope that the weather would be better in spring, It’s December now by the way.

Time to start on the interior. After having the experience from fitting out my VW a few years ago I had some ideas of what I wanted to achieve. I like to keep everything practical and functional so after changing my mind for the ‘ilionth time decided to just get on with it. Starting with the roof, I ripped out the aluminium lining and old insulation, removed any rot and red leaded where necessary. This was probably the worst job so far, the insulation got everywhere and I itched for days. I’m sure it didn’t do my respiratory system any good either. I then stuck a heater on and left the van for a couple of days to ensure it was dry and to get over the extreme discomfort of the glassfibre.

After owning a Bedford single decker many years ago, which I panelled out in wood, and remembering the warm feel it had, I paid a visit to the local B&Q to do some pricing up. I was pleasantly surprised to find that a pack of tongue and groove cladding was only £2.48!! That made my mind up for me as I grabbed enough packs to keep me going.

Also grabbed a pack of insulation which was just as uncomfortable to put in as the old was to rip out!!

The roof went in well and after a coat of woodseal looks great.

As you can see from this pic, also decided to paint out some of the windows, these will be insulated and panelled over later, the blue on the nearest window is the tarp outside. The roof was easy to fit apart from the itchy scratchy stuff, I used self tapping screws and secured the wood directly onto the roof supports. Ensuring all the screws are in line gives the job a professional look. I love the result!

Floor in and red leaded, total cost £27 including under seal. Quote from garage £500!! Does make you wonder?

I wanted a nice big area to chill out in, the VW was much loved but it was hard to get comfortable with any more than one reasonable sized adult in there, the whole of the rear of the Dodge therefore would be reserved for sprawling out, this would also double up as a double using the dining table to fill the gap in the “C” shaped seating area. This meant that the rear doors would be panelled over which I don’t mind at all. Against the back door under the seat I installed a 150 litre water tank. This was by far the most expensive item so far at over £100 but after running out of water in the VW on more than one occasion and having to totally break camp to drive off to find some I figure it’s more than worth it.

I’ve made the two seats that run down the sides of the van wide enough and long enough to be used as single beds if need be in case me and Katie have an argument and want to sleep in separa……………. Only joking, for when the kids are with us. This left the problem of another bed for Katie and me. After lots of ideas, scribblings and suggestion the solution has been to construct another double bed over the seating area using spars and lats that could be removed and stowed when not required.

After seeing the “Bunk” bed starting to take shape, I think it’s going to work fine.

I have used some rounded skirting board on top of the spar against the back doors to make a slot for the lats, these are stepped away from the spar to the depth of the cladding to enable the job to have a flush finish.

Panelled the rear of the van and the “bunk” slot worked out fine.