revival retro From removing old coverings to refitting and before All the extra info you need for your campervan redo. Beep, beep!

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1 AUGUST 2015 AS SEEN ON before The classic orange paintwork influenced the new interior scheme. All the extra info you need for your campervan redo. Beep, beep! From removing old coverings to refitting and adding the finishing touches, this pattern sheet takes you through the steps of a Kombi refurbishment. It includes kitchen cabinetry, a table, curtains and a reupholstered seat and bed combination. Start your engines! 1 BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au

2 The ideal spot for a cuppa! A new table with design, finished with aluminium flat bar trim around the edges. Begin with a clear idea! Before you commence, create a mood board of what you want your finished van to look like. Drawing inspiration from the outside colour of your van, lay out a selection of complementary fabric samples for seats and curtains, choose paint colour chips for cabinetry and select any new hardware. Do your research and make sure all the supplies you need for your van refit are available then get going! Mimic the old interior layout, adding new painted ply cabinetry, vinyl flooring and upholstery to boot! 2 BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au

3 KOMBI REFURB Gather your supplies n Vinyl flooring in colour and finish of your choice n 6mm marine plywood (used for interior wall linings) n 12mm marine plywood (used for cabinet faces, doors, and seat fascia) n 18mm marine plywood (used for cabinet panels, bench top and table) n Kombi seat-to-bed mechanism, to suit You ll Also Need Utility knife; double-sided tape; aluminium floor trim; drill, bits and countersink bit; pop rivet gun; stainless-steel pop rivets; power saw; handsaw; jigsaw; PVA; wood filler; sandpaper; undercoat (we used Dulux 1 Step Acrylic Primer, Sealer & Undercoat); semi-gloss enamel (we used Dulux Super Enamel Semi Gloss in Vivid White and Quince Jelly); clamp; 30mm wood screws; L brackets; 15mm and 30mm stainless-steel pan head screws; piano hinges; hacksaw; cupboard door handles; 20mm aluminium flat xbar; construction adhesive; painter s tape; clamps; fine sandpaper; rust converter; paint brushes; spray paint for metal Notes 1. All plywood components are pre-painted prior to installation. Apply an undercoat and two topcoats of semi-gloss enamel to plywood components, following manufacturer s instructions. 2. Adjust material quantities to suit your needs. 3. Use the following information as a guide only. You are responsible for checking all rules and regulations with relevant authorities that may apply to the refit and safe use of your motor vehicle. Here s how CLEAR THE SPACE 1 Remove old cabinets from van. Since these will be used as templates for the new cabinets, take care when removing and dismantling them. Take note of which piece goes where so you can easily rebuild it later and take lots of photos throughout the process for future reference. Carefully remove upholstered items (padded seats and mattress), fabric curtains, vinyl flooring and old seat mechanism (this is the mechanism that allows the back seat to fold out to a bed). Keep old hardware in safe spot, clearly labelled just in case. If necessary, take upholstered items to a tradesperson to have them recovered. Stitch up a new set of curtains in your fabric of choice, copying dimensions of old ones. Discard unwanted items. REFITTING THE INTERIOR 2 Lay new vinyl flooring on floor panel inside van. Using sharp blade of utility knife, carefully trim excess vinyl around edges of floor at walls and at door. Secure vinyl to floor panel using double-sided tape. At door, place a strip of aluminium floor trim over cut edge of vinyl and screw trim to floor panel to secure. 3 Carefully remove old wall lining panels and use them as templates to mark and cut new wall panels from 6mm plywood. Check new panels for fit on walls of van. Adjust if necessary. 4 To secure wall panels, drill holes for pop rivets through new wall lining panels and body of the van behind. Place pop rivet into rivet gun and push through a hole. Pull the trigger on gun to tighten rivet until panel is fastened. Repeat for all fixing points, placing sufficient rivets so panels are firmly secured. 5 Place a sheet of 18mm plywood face down on your workbench. It s important plywood sheet is face down as power saws cut on upstroke, meaning a cleaner finish on face of boards. Place each old dismantled cabinetry piece face down on plywood sheet and use a pencil to trace around them. Clearly label each so you know where it goes later. steps BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au Better Homes and Gardens fan Anastasia, 15, took up a job delivering papers when she was just 10. By the time she was 14 she had saved enough money to buy what she d always wanted a VW Kombi van. This one is a 1974 model and was looking a little tired and in need of some lovin, so Better Homes and Gardens TV presenters Adam Dovile and Demi Harman came to the rescue. 5

4 The old stove behind the passenger seat made way for a padded storage box the ideal spot to keep picnic gear for when you pull over and enjoy a lazy afteroon in the sun. Don t forget to pack the chairs! 6 Cut out all required components. To do this, cut along marked straight lines using power saw, stopping at any internal corners. Finish the cuts at corners using handsaw Use jigsaw to complete any curved cuts. 8 Where necessary, mark lines of shelves on inside of cabinet side panels. Drill an even spread of pilot holes on the side of line where shelves will sit. 9 Turn cabinet side panels over then countersink pilot holes on outside face of panels using drill fitted with countersink bit Assemble all cabinetry. Apply PVA to shelves and butt into side panels. Predrill shelves through countersink holes, then glue and screw in position. 4 BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au 10

5 Job done, crank out the tunes on a -look wireless. 11 Use wood filler to fill screw holes. Let dry. Sand smooth, then wipe away dust. Apply undercoat and paint in 2 coats of white enamel. Let dry after each coat. 12 Place cabinet units in position in same configuration as before they were removed. Make front edges of units flush and clamp together. Predrill, countersink and screw together using 30mm wood screws Secure cabinets to walls and floor using L brackets and 15mm stainless-steel pan head screws. 14 Cut cabinet face panels from 12mm plywood. Apply undercoat and paint in 2 coats of white enamel. Let dry after each coat. Fit face panels in position. To do this, screw through face panel into cabinet using 30mm stainless-steel screws Cut doors to size from 12mm plywood. Apply undercoat and paint in 2 coats of white enamel. Let dry after each coat. Using hacksaw, cut piano hinge to size, screw 1 side to door then screw other side to cabinet face panel using supplied screws. Drill holes in doors for handles and attach handles to doors. 5 BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au 13 15

6 The seat-to-bed mechanism allows you to recline right back, creating a cozy bed where you can enjoy a good night s sleep. Sweet dreams! steps 16 Position new seat mechanism in van and bolt in place. Copy the old fascia of seat onto 12mm plywood. Cut out, paint and install. 17 Before installing benchtop, screw L brackets to cabinet sides, flush with top of cabinet On 18mm plywood, mark and cut benchtop to sit on cabinets. Install benchtop in position then, from underside of benchtop, screw through L brackets to secure. Refit items such as sink and plumbing fittings. Cut 20mm aluminium flat bar to suit benchtop edges. Spread construction adhesive along edges, press aluminium into adhesive, flush with top face, and use 15mm screws to hold in place. 19 Using 18mm plywood, construct a simple open-topped box unit to go behind passenger seat. Butt-join corners of box, predrill, apply glue and secure with screws. Use L brackets to attach unit to floor. 20 Cut 2 panels from 18mm plywood, 1 to match external dimensions of box and 1 to match internal dimensions. If you wish, have larger panel upholstered. Screw through smaller panel to base of larger panel to make a lid for the box. 6 BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au

7 The table is removable, but in its upright position there s enough space for a few people to dine and enjoy. 24 MAKING THE TABLE 21 Using old table as template, mark and cut new table panel to size from 18mm plywood. Undercoat and then paint table with 2 coats of white enamel. Let dry after each coat. 22 Clamp aluminium flat bar to 1 long edge, flush with square end. Tightly wrap it around edges, excluding the edge that will attach to wall. 24 You can leave your table white or use painter s tape to mask up any design you wish. For a diamond pattern like ours, apply 2 evenly spaced strips of painter s tape, centred to the length of the table. Mask up an even spread of diamonds between the 2 long strips. Paint diamonds in 2 coats of orange enamel. Let dry. Remove tape. If you would like to create an overlapping diamond pattern like ours, mask up a new series of diamonds offset to the first. Paint diamonds in orange enamel. Let dry. Remove tape. 23 Remove shaped aluminium and apply construction adhesive to sides of table. Reposition aluminium on table edge and press into glue so it s flush with top face of table. 25 Attach old table fittings Predrill and attach aluminium with to cabinet for table to clip into and 15mm screws, evenly spaced. also attach fittings to table BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au

8 PAINTING THE BULL BAR 26 To revive a rusted metal bull bar, sand over surfaces with fine sandpaper to remove any surface rust. Brush away dust. Use a paint brush to apply a coat of rust converter to surface to prevent future corrosion. Let dry. 28 STOCKISTS Project supplies: Power tools, Bosch Australia , bosch.com.au 2440 x 1220mm hardwood marine plywood, 18mm $134.50/sheet; 12mm $78/sheet; 6mm $43/sheet. 48mm doublesided tape, $6.64 per roll. Roberts 1.65m pewter floor trim, $ Stainless-steel pop rivets, $7.50/120pk. PVA, $16/500ml. Timbermate woodfiller $8.76/250g. 30mm wood screws, $3.68/25pk. 50mm angle brackets, $4.26/4pk. 10g x 15mm stainless-steel pan head screws, $16.56/100pk. 10g x 30mm stainless-steel pan head screws, $24.78/100pk. 610mm piano hinge, $ mm chrome door handles $12.50/2pk. 20 x 3mm aluminium flat bar, $14.51/3m. Heavy-duty construction adhesive, $5.20/350g, Bunnings (03) , bunnings.com.au Back seat-to-bed mechanism, Classic Vee Dub (02) , classicveedub.com.au 1 Step Acrylic Primer, Sealer & Undercoat, $74.35/4L. Super Enamel semi gloss in Vivid White and Quince Jelly, $85.15/4L. Dulux Metalshield spray paint, $9.95/300g, Dulux , dulux.com.au Geometric fabric (used for curtains), Spotlight , spotlight.com.au Tartan fabric (used for upholstery), The Fabric Store, (02) , thefabricstore.com.au Shopping details: Orange marquee PVC folding chairs, $19.98 each, Bunnings Warehouse. Opposites Attract cushion in Grey and Coral, 45cm $45. Castle and Things velvet round cushion in Pink, $49. Beach Boy tumblers with three stripes, $45 each, Koskela (02) , koskela.com.au 27 Protect surrounding areas of vehicle with a drop sheet, plastic sheet or thick cardboard. Spray bull bar with 2 3 coats of a suitable metal paint in colour of choice. Let dry after each coat. FINISHING TOUCHES 28 Fit upholstered seats and mattress inside van looking good! 29 Fit curtains in place and you re ready to hit the open road. PRICES ARE INDICATIVE AND TO BE USED AS A GUIDE ONLY. 8 BETTER HOMES AND GARDENS, AUGUST 2015 bhg.com.au