With the water tank filler in position the next task was to fit the tank so that the kitchen unit and a seat can be built around it. The tank is a 70 litre unit from Fiamma that comes with long threaded bars, nuts and washers to attach it. Before it was installed I cut the openings for the fill pipe and breather, put an outlet union in the rear side and attached a submersible pump to the union.
The threaded bars supplied are not long enough to go through the two sheets of ply and insulation as well as the metal of van floor, so I have bolted two pieces of half-inch ply through the floor and attached the tank to them. I used a heat-gun (used for paint-stripping) to gently heat the inlet pipe to make it more flexible before attaching it and the breather pipe to the tank with Jubilee clips.
The frame for the kitchen unit is again assembled using simple halving joints, with a couple of diagonal braces across the back for fore & aft rigidity. Solid ply panels at the front and rear should give side-ways rigidity. The frame is bolted through the floor and also attached to the van inner skin (sheet metal) with self-tapping screws. Braces and attachments will be hidden with a plywood lining in the cupboards.
There is also to be a high level cupboard above the kitchen unit. This will be supported by the large batten behind the ply (below, before the ply was fitted) and 10mm thick plywood sheets from floor to ceiling at each end of the unit.
The plywood sheet at the front of the unit will form a vertical cupboard with a parallel sheet. That cupboard will also house a box with switches and a radio in it.
Before cutting sheets for the ends I had to know the final dimension of the base unit. The cupboards will have sliding doors and I had no runners. Searching local stores and the internet I could find nothing suitable. All modern sliding doors seem to have elaborate roller systems. Plan B? make my own! Very simple, just screw the right sized pieces of wood together.
The channels of the upper runner need to be deeper than those of the bottom runner. The door (10mm ply) is then lifted into the upper runner and lowered in to the bottom runner.
To cut the ply to the profile of the van wall I first temporarily attached a piece of scrap ply to give the inner edge of the panel (the darker piece in the picture below).
The panel is then clamped to this guide parallel to the edge. Measure the the distance from the edge to the guide (100mm). Measure the same distance (100mm) from the van wall and mark on the sheet at approximately 50mm vertical intervals.
Joint the dots and you have a line to cut to.