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Transitionpilot wrote: ↑Sun Sep 07, 2025 10:31 am Great job on the insulation, those wheel arches are a work of art!

Thanks mate! That hex pattern on the sound deadening makes it pretty easy to conform to all the bends and creases so it wasn't too bad a job.

The lack of internal tailgate release was a bit annoying, so knocked together a few mating connectors for the tailgate switch and a generic tailgate release button. No need to splice into any wires.



Then finished insulating the tailgate, this time with the Kiravans 35mm fleece.



I actually bought the 35mm fleece for the roof, as it sits flush with the beams that run across the roof panel. That means it shouldn't compress when I add a ceiling panel.



Then played around with the carpet that just arrived, it's ATI high flex velour from Mega Van Mats. Really nice stuff, a bit thicker than I expected so will have to think about not spacing panels out too much etc. Only did the tailgate ply panel today.



The camera flash makes that gap at the top left look way worse than it is. The tailgate sounds really nice when it shuts now, better than any VW I've owned before, and the tailgate release is a massive improvement.

Insulations done beautifully

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gazza31112 wrote: ↑Tue Sep 09, 2025 8:06 pm Insulations done beautifully

Cheers Gazza!

Debating how I should finish off the rear side "window" areas. I don't want to carpet straight over the insulation but not quite sure how I'm going to add infill panels. Don't want to panel the entire side like the original ply kit...

Forgot to add, I picked up a set of second hand Climair wind deflectors. Still undecided whether I'll add forced ventilation, so these will allow me to crack the windows while I make my mind up.

That release button is a great touch and looks like it's always been there, top job!
If you're this meticulous with everything you do I imagine this van is going to end up looking show worthy!

Transitionpilot wrote: ↑Tue Sep 09, 2025 9:33 pm That release button is a great touch and looks like it's always been there, top job!
If you're this meticulous with everything you do I imagine this van is going to end up looking show worthy!

Pretty pleased with the button, thanks! That's high praise coming from someone who's bothered to clean their arch liners - that's next level attention to detail

Minor update, added my Skoda door pocket bin, this has been in my last 3 cars and has been brilliant. OEM part from Skoda and only about £15!

Part number is 5JA0611079B9



Needs a clean really.

Exciting day! My composting toilet arrived! Wrote a little motivational letter to myself on the lid... (Image quality isn't mint, but it says "It's better than sh*tting in a bush ")



If anyone's been considering a BOXIO toilet, it's pretty good, but hugely overpriced. It's a standard euro crate with a 5L liquids jug and essentially a food waste bin for "solids". You're essentially paying for a nice separator insert.
It also doesn't come assembled which is a bit of a cop out as it's not like it saves any packing space! Definitely don't buy the unbelievably expensive bags, as it fits a standard 5L biodegradable food waste bag.

Anyway...

Carpeting the bulkhead sides has terrified me for a while, but it actually wasn't that bad. Trim fix glue on both bits:



Once the glue has tacked up, apply the carpet. This needed a fair bit of stretching and working around the curves. I trimmed around the edges, leaving plenty of overhang to tuck around the back, and cutting reliefs for the corners.



All sides tucked around the back. I was worried this would make the edges too thick but a test fit confirmed that it still fits well in the van.



Pretty pleased with that outcome!



Smoked some holes to allow the bolts to go through - did this with a hot piece of wire.



And fitted, looks way better and covers up the seam left by cutting the rest of the bulkhead out.

Picked up some Touran bases and seats today - £120 for both pairs, not bad at all!

Out with the old, and a clean underneath...



New base in...



And in with the new...



The main reason I got these was to use as a seat for the rear, in lieu of a proper swivel seat.



Bonus is they have little tables on the back.



Both seats fitted, so much better! Way comfier, adjustable lumbar support, and go a little lower too.



One of the tabs for the storage bin under the passenger seat had broken, so I made a replacement from some angle aluminium. Bolted and epoxied on.



Interestingly (which I haven't seen mentioned, maybe it's in the how to section which I don't have access to!) I had to cut the airbag plugs off my old seats as the Touran seat and the van had the same gender of plug. Crimped (with an open barrel splice - you'll never see solder on my car...) and heat shrinked, then wrapped with loom tape.

Great build really enjoying seeing it come together. Those seats look so much more integrated than the basic Caddy ones. Being able to drop the passenger one down really opens the space up.

PJD wrote: ↑Sat Sep 13, 2025 6:33 am Great build really enjoying seeing it come together. Those seats look so much more integrated than the basic Caddy ones. Being able to drop the passenger one down really opens the space up.

Cheers PJD! Yeah these seats are great, I originally wanted a swivelling passenger seat but the options for these seem super limited. A flat folding seat was the next best option!

Slept in the van for the first time last night, before a 50km ultra marathon in the Peak District. Just chucked a foam mattress in the back and it worked really well, had a really comfortable night's sleep. Such an upgrade from sleeping in the back of my Scirocco, ha.

Well done on the 50k. That's a serious athletic achievement.

Being able to kip in the van is a great milestone. I remember when I had mine at that point.
It's actually a lot of work to get to that point.

PJD wrote: ↑Mon Sep 15, 2025 4:55 pm Well done on the 50k. That's a serious athletic achievement.

Being able to kip in the van is a great milestone. I remember when I had mine at that point.
It's actually a lot of work to get to that point.

Cheers, it was pretty tough! Limped a good portion as one of my IT bands gave up part way through, haha.

I think it's definitely good to start using the van for the reason I bought it, and it's a useful way to start getting an idea of whether my idea of a layout will work well.

That boot release button is great
Would it work for a barn door ?
Would love a good write up on it

The trim on the bulkhead sides has come up looking OEM, well done

Those Touran (??) seats look very versatile n the trim looks smart
The fact that the pax seat folds down forward n also has a tray makes it very functional

50km, kudos to you
Not much u can do for an ITB while out in the middle of a race, need a few passes on a foam roller - agony !!

Glad you had your first of many nights in your van, makes all the hard work worth it

Speaking of which, I reckon your van is in better / cleaner condition than when it left the VW factory !!