Cutting more holes in my Sprinter Camper Van
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- Опубликовано: 29 авг 2024
- Mercedes Sprinter Camper Conversion - External Hook Ups
Cutting lots of holes in the side of our van for all the services.
We are fitting external connections for Autogas, Electric and Water.
We also had to cut a large hole for the shower extract vent.
The hole saws I used were Erbauer Bi-Metal Hole Saws.
They do a wide range of sizes and I could pick them up locally.
If you would like to purchase them online here is a link:-
rover.ebay.com...
Another excellent make is Starrett and a link to their Bi-Metal Hole Saws is here:-
rover.ebay.com...
Disclosure - As an eBay Partner, I may be compensated if you make a purchase using the above affiliate link. Thank you for supporting our channel.
The recommended location of the Gaslow connection is on the skirt of the vehicle below floor level.
This is in case there should be a leak on that connection it will easily vent as it's outside under the van.
I plan to build a sealed gas bottle chamber with a drop-out vent through the floor.
The Autogas connection will vent into the sealed gas bottle enclosure if there is a leak.
The entire gas system will be pressure tested and certified by an LPG gas-safe engineer.
We have more holes to cut in the floor for the waste and water pipework, plus the gas pipe.
We also have a hole to cut for the boiler flue terminal and solar panel cables.
If you have any questions about any aspect of the build please do leave a comment.
Make sure to subscribe and click the notification Bell for the next episode. If you have found this information to be helpful to you and would like to make a donation to help fund future videos please visit www.paypal.me/...
Thank you very much for watching. #gregvirgoe #vanlife #tinyhome
Backer board during drilling is a brilliant idea. Thank you!
It works really well at keeping the pilot drill steady. Thanks
About to cut into my van. Watching this has helped no end. Cheers.
Greg been watching your channel for a while now and just offering an alternative to the the backing block when drilling large holes in thin sheet, in the electrical trade we used to drill the pilot hole the right size (1/4" lets say) then replace the pilot drill in the hole saw with a plain diameter piece of steel (1/4" Diameter) to act as a mandrill to help guide the hole saw through the sheet with no wandering, never failed for me, hope that helps someone :-)
Nice to watch a video where it is all done right, you are leading the way in van build videos.
Much appreciated Mike. Thank you 😊
Brilliant. Really good to see someone doing the job properly without any bodging. Your hints are really great. Thanks!
Thank you very much.
I don't know if this has come up before but a good way of painting over the raw edges without having to waste of clean a brush is to use a cotton bud.
The attention to detail is impressive, can't believe anything that would come from a bespoke factory would be anywhere near as good as what you turn out...priming raw edges, that would never get done at a factory. Also using a timber pattress for rigidity, obviously you've put an awful lot of thought into everything you fit, brilliant.
At first, I was just watching the videos that pertained to what I was doing on my van. But the more I watched, the more I learned about the methods used by a master craftsman! I am going to watch them all, and my van build will be the better for it. Thank you, thank you for helping out so many people!
Hi Lynette, thank you for your lovely feedback. There are little tips and tricks in each one that you can apply to all sorts of jobs :D
You are amazing! Don't even have a van yet but I know it might now be possible. Thank you
Oh it’s definitely possible Stephen, many people with no experience have built amazing Campervans 😃
Absolutely genius with the board behind when using the hole saw. That's one that I'll be borrowing.
Slev88 it really does help keep the cutter steady.
Greg, Today I spent the day at the Kennedy Space Centre marvalling at Man's greatest achievements, but after just watching this I will not dream tonight of Space, I will dream of drilling holes, the right way, with a backing board. If I'm lucky I might even dream of gooing a flange or four!
Your comments are always guaranteed to raise a smile Karl, you do make me laugh.
Was there a slight innuendo there, I like to think so 😂 lol
Just watched all of your van convertion videos in a single sitting and I ain't even building one. Really made me wanna get one. Knowledge and method, great series
Thank you for watching all the videos, much appreciated
Thanks for that Greg I’m sure your methodical precise and no nonsense approach inspires confidence, that others may consider tackling jobs they may have previously been reluctant to attempt
That’s exactly my aim Paul. Hopefully these jobs are not beyond anyone with a bit of guidance and advice. Thank you
Brilliant Greg, another well thought through and informative video that is a real help to other self build projects. Keep up the great work.
Thank you steve, I hoping to inspire anyone to have a go at doing their own build. Thanks for a great comment. 👍🏼
It's a joy to watch someone who is as much a pedantic perfectionist as myself.
I am most definitely that lol
Pleased that you are enjoying them
Thanks for sharing the tips on cutting holes in thin sheet metal,,, Great Tips,,, Best Regards
Old Guy, you are most welcome, thank you
Hello Greg
Thank you so much for your clear, concise and meticulous videos they really have been very enjoyable and informative to watch; Im in my mid fifties and due to an impending huge life change, worrying about the impact of Brexit on the housing and employment markets and faced with an imminent company restructuring and potential unemployment, I have been flirting with the idea of living in a van full time for about 6 months now; however, buying a purpose built RV or converting a van and fitting it out seemed completely impossible.
To my shame and regret I have no mechanical, electrical, plumbing and carpentry skills or experience whatsoever but your tutorials have given me the confidence to believe that, with a bit of help in places, it might actually be possible to undertake most, if not all, of the work myself.
Sorry for the mini life story but I can't tell you how much this video series has helped keep me going, both in terms of a general educational pov and from my own personal interest. It really has given me a feeling of hope. Thank you so much Greg!
Are you going to cover how you built the sealed enclosure and vent for the LPG tank soon? (Welding is yet another skill I've never learned)
Thank you for such great feedback and sounds like you are planning big changes much like myself. We will be living in our van full time in a couple of months from now.
I will continue to document every part of the build to completion. Best wishes
Hi Greg. You may not believe this, but I was up late researching refillable LPG cylinders, and I was just about to go to bed and saw that you had put this video up.
Needless to say, it's absolutely up to your usual very high standard, and has helped me consolidate my thoughts on refillable cylinders, so thanks very much for that.
Regards Mark in the UK
I'm glad I'm not the only one burning the midnight oil on van research. :D
What were your thoughts? Are you going for a refillable system?
Yes I will. The quick research I did just last night showed 'Gas it' and 'Gaslow', and because cost is ALWAYS an issue, I'll probably go with 'Gas it', since at the moment they appear quite a bit cheaper (less expensive). My research (up until the time of this reply) hasn't gone as far as finding out whether an existing cylinder - say from a BBQ can be used legally AND safely. It's just that I have a spare 11kg BBQ cylinder and I seem to remember reading (on one of the sites) that it's possible to have a 'spare' cylinder as a back up; with appropriate adaptors etc.
I'm sure I'll get to the bottom of it, but what's your take on using an ex BBQ cylinder?
Brilliantly neat work on your Sprinter btw, and I particularly liked the use of the plywood backer to help stabilise the holesaw.
I think I mentioned the other day about pm'ing you at some time with a few specific questions if that's ok. Would messenger be ok with you, maybe later today?
I've been checking out the van life and van build scene (before it blew up on youtube) for a number of years now and your videos are a wealth of information and meticulous care. I think you and Jaz (Travel with Jaz) have really innovated the whole van build concept. Keep the videos coming and great job!
Hi Stevil, yes I too think Jaz videos are brilliant and I’ve been following his build with great interest. He being an electrician you can see in his electrical video particularly well executed and planned out. Thank you very much for your kind praise. Much appreciated 😊
Using the piece of wood to keep the holesaw correctly positioned was a fantastic idea
Just a bit more meat to keep it from wandering around.
Fantastic as per usual... you have an amazingly calm and clear way of explaining it all. 👍🏼👍🏼
Pleased you like the videos. Thanks
Oh yeah, backing plates. I have become a big fan of them myself, especially since every hole I cut into the hull (especially if it is below the waterline) fills me with trepidation. ;). Lots of great tips in this video!
Thank you Greg, I had been put off cutting out the peculiarly shaped hole for the hook up connector. You told me that cutting out the shape would be difficult and inaccurate with a jig saw and that you used a hole saw. So I am going to follow your example. The connector is an absolutely pathetic design with no thought given to installation. My product has a pathetic and ineffective cable restraint system. Pity the English and Italians can't learn from the American designs. Thank you again for using the hole saw it has saved me a load of anxiety cutting out that stupid shape. Regards
Love the way you care for all details. Great job again, as always. Thanks for sharing!
Thank you for the continued support Marcos 😊
Quality tutorial that covers all steps and little practical tips for other projects. Keen to see more and keep up the good work!
Thanks for your support
Thanks Greg for the video - some excellent tips there and nice to see them being demonstrated :)
Thank you Adrian. 😊
Care for crucial details here is completely nuts!!! Subscribed 😁
mirogster fantastic feedback 😀
Lovely work as always Greg. Nice one.
Thank you Roy 😊
Its a joy to watch your videos Greg
Well done mate
Spot on
That's great to hear, thanks
Best thought out and executed van upfit as always Greg!
Thank you John, Always appreciate your comments.
Nice tidy work as always Greg thank for sharing
Much appreciated.
Thank you for the helpful hole drilling techniques. Can’t wait to see your next video.
You're most welcome Jesse, Thanks for the support
Well done Greg, really useful tips in this video especially using wood behind the holes. Looking forward to the next one...!
Thank you chris, hope you enjoy the rest.
More great tips that are going in the notebook in preparation for my own van build in the spring. Thanks for sharing, Greg!
Here's an idea for you. Design a solar vacume tube hot water heater retrofited to super heat gallium. Use an electromagnetic pump to circulate the super heated gallium through a copper heat exchange coil within an insulated tank filled with water. Then add in thermal electric generators to the system. You could even design an absorption refrigeration system to operate a fridge or even cool your van on a hot sunny day since you have a well insulated van. With the heat wave in the UK thought you might enjoy these ideas. 😊
I had to google it but it would appear to have a very low melting point, so it's change of state could be used like a refrigerant, interesting comment, thanks
Thank you again this is GREAT! I'm learning so much. I can't wait to take a woodshop class to learn how to use all of these tools.
Hi sheri, as long as you are careful and use correct safety equipment nothing stopping you having a go and just practice on some scraps until you feel more comfortable with using the tools. There are loads of great beginner videos on here of course.
Learning so much from you! Excellent job even though I’m doing a Ford Transit ..., just as well
Hi Steven, these principles apply to any van conversion. Thank you for your support.
Another awesome video many thanks for the instructions. I’ve been a bit concerned about cutting holes in the van but as always you’ve made it look easy 😁
Hi Kerry, I can give you a few words of advice using these hole saws. Apply light pressure against the van, do not push hard or the teeth will dig in and may catch. Have a firm grip on the drill just in case it does catch a little and tries to snatch the drill out of your hands. Slow and steady is the best way forward. Hope that helps. Thank you
good idea using the wood backer
I just know form many a really poor cut hole that these cutters are really violent and the teeth are too aggressive so you need something to reign that in a bit.
Greg, excellent videos. I discovered your videos today after spending the Canadian Spring and Summer researching DIY Camper van builds. Keep up the excellence.
Hey, Greg congrats for your 100k subscribers! Thanks for all your support!
Great tip there with the sacrificial board! 👍🏼
Yes, it works really well at keeping the arbour still
Top tips again. In Greg we trust !
Great tip, screwing the wood on and drilling into it.
It works really well dave, thanks
Cutting holes are scary...thank you...👍
Hope that has given you more confidence 👍🏼😃
Very Nice
Thank you
Thanks again Greg for another well presented video which meticulously demonstrates how to do a job right, first time. Everything you do is quality and I admire you for that. I always look forward to your videos as I have a similar dream of building my own camper van too. I'm into motorbike as well and also paramotoring so I want to travel around the UK and europe in my van doing both of those, probably next year. My only slight concern is that having such a large garage does make the lounge area very confined and I think that may make me feel a little claustrophobic and not comfortable. I think that you should tell your boss that since you've had this van, you don't have the time any more to go to work. Then you can really crack on with the project, bang out more top notch videos for your followers and then enjoy the free nomadic life sooner. All the best mate. 👍
Funny you should say that Ian, I had the meeting last week, big announcement coming very soon. Exciting times ahead.
smart gas storage idea Greg thanks for sharing your idea
Thanks, I didn't want to have to keep changing bottles, this way I can just fill up LPG at petrol stations, about 62p a litre at the moment. The maximum my tank holds is 22.5litres so that's £13.95 to fill it up. That's half the price of most bottled gas.
Great tips for adding hook up connections.
Thank you Kelly, glad you liked it.
I've just got around to fitting my LPG pipes although I bought mine from gas-it. I bought a version with a rubber boot for the inside, which connects to a plastic pipe that leads down through the same hole as the filler hose. It saved me from building an enclosure.
Very clever with the wood backer!
It really does help to keep the centre drill bit steady and make your hole neater
Great job as always, well done on pointing out Gas Safety..... also equally important is the flueing of your Combi...CO is a very dangerous thing as I’m sure you’re aware.
Yes, I Plan to have dropout vents where each gas appliance in the van and CO monitor and gas detector inside the van also.
Funny I was just getting around to doing this job. Great timing, thank you.
great idea with the support wood, will use that myself.
It's really important to keep that pilot drill from chewing a bigger hole in the sheet steel.
Excellent tips, thanks. You make it look so easy ....
With new drills and cutters and the right technique, it makes the job easier.
If unsure practice on something scrap to start with so you get the feel of it.
Thanks for great feedback.
Great vid as always. So frustrating that no one seems to produce the main 3 external connectors with a standard look and fitting. I see why so many people end up getting creative in where they locate the various connectors.
Good tutorial Greg👍
Thank you Norman 👍🏼
Hey Greg can you advise me on this 🙏:
Hi Greg - help please!😀 just about to insulate floor of shed with 25mm PIR. The shed floor is made of treated timber not T&G so not so close boarded and the floor is supported by timber battens on a concrete base. Do I need to buy a breathable fabric membrane between PIR and floorboards? I will be making up a support structure of 25 x50 treated battens on a grillage of 2’x2’ to support the new plywood floor - the PIR will be sandwiched between the plywood and the floorboards - I will be using the foil tape to bridge between panels and maintain vapour seal at to top surface of PIR but a bit concerned at the interface between bottom of PIR and floorboards even with the small gaps between floorboards. Sorry for long explain!😳
Floors for buildings and sheds Norman are different in their requirements. The location of the vapour barrier is used to prevent moisture coming up from the ground below. Best to install a vapour barrier first then insulate and floor covering on top. Cheers
Understood - many thanks. I think I sort of knew the answer but when the expert is around I thought it would be best to consult. Once again many thanks.:-)
Very nice and detailed explanation - well done!
Thank you very much
Hi Greg! I'm very pleased to see the achievements you have done on this project so far. I have been researching for a while now so I have an idea about how difficult it can be. I am planning to go through the same process in the near future. Therefore, if you think I can help you in anyway please let me know. I will be more than happy to meet you and bring in the best of my contribution and knowledge. Kind regards, Bogdan
Thank you for the offer and glad you are enjoying the build series.
What are your own plans?
top effort again there Greg.
Thank you once again Nell, :D
oh this is exactly what I needed to know! Thanks for your clear info and demonstration!
Really pleased it was useful to you martha
Hi Greg, after watching this video I was thinking how to put down my thoughts in words but after reading Ian H.'s comment there is nothing I could add to that really. Even his idea of telling your boss sounds excellent to me. ;-) . ATB Marc Belgium
Hello Marc, I would love to have more time to concentrate on this channel. Work does sometimes get in the way but it pays the bills 😊 Thanks for your support.
Brilliant 👍👍👍
Cheers 🍻😃
Well done Greg hope you have fab weekend Mate :-)
Thank you Malte, we are loving the whole community vibe, everyone is so super friendly and met loads of fantastic people.
Nice to hear that Greg, :-)
Great tip with the back booard.... al be giving that a go layer today... cheers...
Greta ideas and ways 👍 cheers for the help
greg thank you for the uploads you have gave me the motivation to give my own build a go keep up the good work
I'm really pleased to hear that, glad they have helped you.
What sort of thing are you looking to build?
Very sensible to screw a block behind the hole. The other big advantage is you don't drop filings inside the van.
It must help a little, but they still got everywhere and always a big clear-up job.
I was actually wondering that you - just for safety - didn't mention this in the video... especially as there ususally are those cavities at the base of the panels where they meet the bottom frame of the van. You certainly wouldn't want anything rusting away there...
My beautiful assistant got down there with the long nozzle of the Henry hoover and gave it a good clean out.
Swarf gets everywhere.
maybe there is a magnetic cloth material that you can stuff down there to attract the filings for removal?
A magnet is not a bad idea at all. Nice one!
Great tips. Your work is so precise.
Thank you 😊
@@GregVirgoe I made a good start getting my plastic panels off, back is killing me on day 2 😂
@@sheyedlington9046 take it easy don’t get injuring yourself in the process 😃
@@GregVirgoe I'm following your advise. Going gradually. I got my tapes down, marking out. Of cource it changes day by day. 😊😅
Nice job Greg .
Thank you Mike
Great video, love to see you working. I wish I had such a high standard for quality, but somehow I'm always rushing... 😂
I do make mistakes, not everything goes well first time. But that’s all part of learning.
Those end up on the cutting room floor. I have been saving some video of errors to release a bloopers video after.
Practice makes perfect 👌🏼
Going well mate, great series, 👍👍👍
Thank you very much
Another great video. I'm so impressed by your attention to detail. Every time I think something like, "Now he just has to drill a hole", you show us a better way to drill a hole! Thanks!
I'm always thinking, surely there must be a better way to do this? Often after i've done it :D
Excellent, everything I need to know - thanks
I'm really pleased it was helpful to you
Brilliant job thanks
Fabulous video
Thanks great video so helpful
Pleased it was useful to you
I love your videos. So practical!
Nice work as always 👌
Thanks for your support Michael
@ 2:48 Most excellent tip! Thanks
Awesome work! Love the video!
Thank you very much
Thumbs up to "THE MAN!" AKA Greg (the pro') Virgoe! 😎👍👍👍
Cheers Greg. Andy Kelly uk
Thank you very much Andy :D
Another Great video thanks Greg
I am really enjoying your videos!
Good job.
Thank you John
That foam you removed is EVA foam, so it shouldn't leak as it's a closed cell foam. I'll let you know if it does! I can always re-install it pretty easily.
This really should be IP65 at a minimum so you can at least wash your van with a pressure washer.
These may only stand up to a light shower at best. Not great for an electrical socket lol
During the years I actually had 3 vans fitted with just that standard foam things for getting the electric hookup sockets waterproof. There has never ever been any problem with leaking and/or rusting at those places, so I guess that foam must do the job quite well. I never used a pressure washer on the vans, however - so maybe if that's what you're thinking you'll do, it's possibly better to play safe here...
Maybe I am being over cautious it just didn’t look like the right material for the job.
Have you considered fitting a gas leak detector as a back-up to your gas safety precautions? Not sure where you would place the detector head, but I guess that the leak enclosure you have already mentioned would be a consideration. Great presentation again Greg, informative with some very useful practical tips.
Ed Wild
Hello Ed, a gas detector is a brilliant suggestion. We will most definitely be fitting one. The gas enclosure is the most likely place for leaks. With constant filling and turning bottle on and off etc. The van will have CO and smoke alarm too. Thank you 😊
Hi Greg, after a lot of deliberation, I'm going for an underslung Gas-it 25Kg tank. That way it will save space inside van and stop me worrying about sealed gas lockers. They assure me just 4 M10 bolts will do it. We'll see?
However, spent all day Saturday fitting Truma gas exaust, but made such a dog's dinner of it, spent all day Sunday ripping it out. Next fitting will be a much longer pipe run, which will be easier to fit and increase thermal efficiancy.
Three steps forwards, two steps back!
Hi, an M10 bolt can hold a huge amount of weight in tension. One bolt could hold 3-4 times that weight.
You will notice I didn’t video the Truma exhaust just yet. 😉 Was it the pipe in pipe that was tricky to do or something else? Not happy with jubilee clips in general for gas or water but everyone seems to use them? Best wishes
It's a long story, but here goes.
My transit has virtually every panel curved, making fitting any flush outlet very difficult. I did find a flat panel area at the end of the sliding door rail. Unfortunately, this position inside the van is double skinned, so there was no way to fit the large jubilee clip. So I was forced to Sicaflex the larger exhaust duct to inlet. Not happy with this solution but probably OK.
In my suspect wisdon, I positioned the Truma just 350mm away, which ment quite a tight bend in the pipe. Compressing and stretching the two pipes didn't go well, with the black plastic coating breaking away in places. Greh. . .
To make matters worse the two supplied fixing screws for the outlet are really piddly and didn't bite well into my plywood backing.
Finally when trying to fix the white plastic cover, one of the captive nuts popped out and vanished, the other insisted in just spinning around. Useless design. I gave up then!
I've re-ordered some new pipe and will move the Truma about 900mm away. This should help in attaching the ducting. Also this longer run should make the heater more efficient since more exhaust heat will be scavanged. I'm assuming the balanced flue is heat exchanger. Also a cooler exiting exhaust should be kinder to the paintwork.
Anyway enough of my woes, back to you. Your idea of fixing a sacrificial wood for cutting the large holes, is a great idea. I wish I'd have thought of that:)
You’ll also need a gas drop hole below every connection on a gas appliance as lpg is heavier than air.
RP Woodworks, just an idea right. I have the bottle, cooker and boiler that all run on LPG.
I have purchased 4no drop out vents already one for each location as you mention.
What’s to say I can’t drop my 8mm copper gas lines through the drop out vents to save me cutting another hole in my floor? Feasible? 🤔
Awesome, thank you!
Greg, you are a meticulous S.O.B. You put Dexter to shame.
Lol Matt, sometimes over think things and chews up loads of time 😐
New subr here, I like you do things properly, I will steal your van build in the future😊
Over my dead body :D lol
@@GregVirgoe I'm binging on your build 😂😁
KainanNa Kabayan no problem binge away 😂
One of the finest works ever seen, Just try to use some tape on the body while sikaflexing it keeps it nice and clean
Another good little tip, thank you
@@GregVirgoe I use vaseline, put the parts in place with the screws, wipe vaseline just a small trace on the body, take apart and add sikaflex, then put back to together, sikaflex won't stick to the surface with vaseline on, now clean up, used that method for many years on boat building.
nice one thanks
You are welcome
Really good series. Why do manufacturers make external electric hook up boxes for external use with square sides? The top edge will be horizontal and have no rain shedding capability. Hey-ho that's the way it is. Keep up the good work.
And the top edge has a hinge that you know will let in some water? Not very good design.
Question. Can you zoom OUT so we can see where all these holes are in regards to van. I would like to see height from the ground and spacing. Stepping back few feet with camera from time to time would give better perspective and orientation. Thank you!!!! BTW, this is the best series on van build by far.
Amazing video tutorial Greg. Yourself and travel with Jaz are really setting the standard!
How do you plan on running all your plumbing with the floor etc already in?
Thanks
Keiran
Thank you keiran, I have two underslung tanks for water and waste. The pipes that cross the van to the kitchen will run underneath and come up through the floor. Pipework for the shower will be concealed in cabinetry.
Great videos thanks brilliant
Great video 👏👏👏👏 thank you
hi greg do you know what size cutter you used for the electric hook up box hole