Toyota Hiace dayvan the build begins
Updated: Jun 20, 2018
So the first job was to remove the badly done ply lining, after taking all the ply panelling and ceiling down and the floor up I could see what voids were left for insulating, the client had given me a load of sheep's wool insulation to use where possible, which was great news as sheep's wool is a great eco alternative to the more commonly used kingspan or rockwool type insulation. Sheep's wool takes very little energy to produce, just a bit of washing and pressing 15% of the energy used to create fibre glass type loft insulation, and if thats not enough it also contains certain reactive proteins that neutralise harmful substances like formaldehydes, a real win win.
The ceiling and top half of the van unfortunately did not have a large enough void for this insulation however, so instead the foil bubble type insulation was used in these locations, fixed with spray adhesive. The flooring was in pretty good shape so I would reuse this, any signs of rust from water getting spilt in the back and getting trapped under the flooring were sanded off before being painted with a rustoleum paint and then putting two layers of thick carpet insulation underneath before refitting this wood keep the floor from getting cold and eliminate a lot of the road noise. Next jobs was to cover all the remaining metal with the bubble insulation before covering with 4 way stretch carpet. This would ensure no bare metal was exposed for cold air to condense on (condensation + body panels = rust). This would be my first time using the 4 way stretch carpet and I have to say its great to work with just be sure to use high temperature spray adhesive as the cheap stuff will come unstuck when the van gets hot in the sun. It takes a methodical approach to achieve a nice finish removing any trim, door handles and holds, all the seat belt hardware, I even had to remove the passenger seats in order to access the door pillar. However after these sections were done with the rubber door seals removed before adhering the carpet right up to the edge and then trimming with a stanley knife and the carpet tucked under the plastic trim near the windscreen the end result looked almost factory fitted. I didn't want it to look like the back had been converted but the front was left as it was and this way it just blended in lovely.
Next step was to make some ply panel inserts and cover them with the 4 way stretch, the obvious way to do this and achieve a nice look was to cut the carpet a couple of inches bigger all round wrap it round the back, I had already made sure the rest of the van was done in a similar way so there would be no gaps visible and I'm very happy with the result.
So with most of the carpet lining done there was a few checks made on the van dimensions before we start making the metal frames.