Range Rover Overland camper build diary : part 3

So now it is coming together , we can smell the finish.

haha  not likely , the slow slog is about to begin

1200 airplane rivets drilled , reamed and countersunk

who’s idea was this … oh yes it was my idea. .great crack on then

rear alloy box super light
inside the aircraft type construction of campervan box
cleckos on camper van

the guilty people of doing this..

Chris and Beady
Sticking the floor down

The old rear doors were cut up to make fillet panels from the OEM to the new rear, pro style, actually better than pro, we know we have seen the competition at work,

notice Rory helping and Alex trying to ignore the hard work going on nearby

rory yeti evan and alex jones ignore work at beady workshop

and zoe helping to fit the floor

zoe jones with black hair

The rear box outer is finished, Chris and I  don’t want to see a rivet gun again, but it is very light and Very strong.

bare alumium rear box on camper van range rover

Now to the interior panels, they are aluminium laser cut and bonded with foam and finished with Formica to make it pretty

here are the test panels in CAD , we built these to test the design

6082 aluminium, Formica and then Polyurethane foam to give rigidity

6081 aluminium, Formica and then Polyurethane foam to give rigidity

This is the right hand side cabinets  looking from the wall side notice the trays, and the aircraft alloy sliders to save weight, but don’t ask the price

foam panel interior for campervan
kitchen frame ultra strong lightwieght for camper van

This is the right hand side cabinets  looking from the wall side notice the trays, and the aircraft alloy sliders to save weight, but don’t ask the price


Did I say I CAD modelled everything .. here is a small selection of models, even the cutlery was modelled.

over 500 items modelled for the design

I could not find any hinges or catches to work with the thin light weight units I had designed for inside so I had to 3d print my own design.

3d printed hinges for custom kitchen units in aluminium
Hinges use steel inserts to reinforce bolts, and make them unbreakable
custom 3d printed catches for campervan

This is the door catch, the idea comes from Airliner galley furniture

custom catches for campervan

catch in door locked position, the little nodules are ground off as needed for L & R operation

The cooker CAD model

two ring multi fuel cooker

Custom cooker to take 2 x Primus omni-fuel stoves it can be lifted out and hung on the side of the truck.

This is a test piece I had done to check my design would bend out of one piece of Stainless steel.

modern art camper stove, amazing
cut and bent from one piece of steel
designer multi fuel stove for extreme off road travel

and here’s the finished cooker in the kitchen unit when being test built.

just fantastic kitchen units aircraft quality for extreme camper van design

now its time to fit the windows and rear insulation , interior insulation and finally the interior.

the saga continues -> part 4

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