Air Vents & Roof Skylight
It's a bit nerve wrecking doing any cutting to the bodywork. I used an angle grinder to cut the openings and did this from the outside of the vehicle. Drill a small pilot hole first and use that as your reference point for all your measurements. Make sure you measure carefully from the inside and outside of the van to avoid cutting into any structural members. I used caravan style swivel air vents for the sides and a pop up skylight/air vent (which comes with an insect screen) for the roof.
Roof Rack
The roof racks were welded up from 32mm x 19mm (mostly) rectangular steel tubing and was painted with 3 coats of NS4, a rust-preventing metal primer. Pine decking was screwed to this to provide a walkway between the two rows of plastic storage crates.
Bike Rack
The images below show the scooter placed on the unfinished bike rack for measurement purposes and then the "almost" finished rack with aluminium tread plate. Lights and tow bar still to come.
Jerry Can Holder & Ladder
Measuring and tack welding the jerry can and gas bottle holder. I cut, bent and then riveted aluminium tread plate to the ladder rungs.
Spraying the Rims
Taping up and spraying the rims. I initially sprayed them silver, but later decided I preferred black - which you will see in the final photos of the camper van.
