CUTTING THE FRONT OF OUR CARAVAN OFF!! CARAVAN RENOVATION

[@robertwilson1827]

Kickass man cave! Lucky to have the tools and warehouse at your disposal!🤸‍♂️🤸‍♂️🤸‍♂️

[@nowornever_aus]

Yeah we are very lucky to be able to use it! Most of the tools we are using are my day to day work tools 👍🏻

[@barrymerrick8867]

I was told/read that not to use silicone/rtv silicones for sealing on caravans. It was recommended to use butyl mastic as it always remains flexible and can be removed. Someone at some stage used it for sealing around the skylight in the roof of my Golf van and it leaked. I removed it and used butyl mastic. No more leaks. I also had to replace the vent fan and purchased butyl mastic as the sealant there as well. I am sure that others will have other experiences with silicones.

[@nowornever_aus]

Yeah I e heard that’s some manufacturers are heading in that direction

[@coversadventurecapers2838]

This brings back memories of when we renovated our 1985 Chesney. Hubby had to rebuild front and back wall and a bit of the roof. We also put checker plate squared up on the front on our van too. Hubby actually folded it to make the tool box.

[@nowornever_aus]

Sounds great!

[@johnpitt2742]

I AGREE THAT it will be easier to have flat surface rather than have curves, keeps it faster to work on and easier

[@marnibarratt8805]

your hair looks amazing that colour & Alex looks amazing with short hair definitely looks better xxxx

[@nowornever_aus]

Thank you!

[@1982mrbigred]

Ex van tech here,when re sheeting silicone each sheet together when u slide them in place of each other,ud be surprised how much water can go up and in between each sheet especially the front sheets when travelling in the rain and traffic passes

[@nowornever_aus]

Thanks will definitely do that!

[@mickp10]

Look perfect with a tool box!

[@nowornever_aus]

😁🙌🏼

[@rebelbright2535]

Water damage is the pits, but most of the time is not the j mould, but actually the clearance lights that let the water in. Hubby is a caravan repairer.

[@nowornever_aus]

Yeah when we pulled the clearance lights off we noticed that they would be a problem!

[@rosemaryshepherdsmith5110]

You both work well together ❤️ Alex is a dam handy bloke to have on board 😊

[@nowornever_aus]

Thank you!

[@danh3065]

Definitely the better decision. It look so much better guys

[@nowornever_aus]

Thanks!

[@phillkettle5856]

You are having fun. Polystyrene is a easy cheap insulation product but it can hold water. Painting the Polystyrene with an acrylic water based paint to seal it solves that issue.

[@nowornever_aus]

Thank you!

[@oconnorfamilyadventures]

Once the tool box goes on it will look awesome. I think it was the right call!

[@nowornever_aus]

Cheers!

[@lizcockram1419]

Love the square look 💪

[@nowornever_aus]

🙌🏼

[@LeonieHall-c4o]

Learning heaps watching you do this. Our vans seem to be glued and stapled together.

[@nowornever_aus]

They certainly are!

[@bushmagpie3312]

If the front rust appears to be from top then the bottom appears to be in better condition. If it was acid then the wood will smell like battery acid. If you are creating an Alum plate front, make your own hatches. You will need a deflect strip under the top sheet, angle to ensure water goes on top of alum. I would suggest a battery hatch in side section as accessing from top will be hard with toolbox in way. You’re thinking it through which is great, don’t rush, most places which sell the plate have companies which will roll or bend it for you. You’re doing a great job as normal Alex guided by your lovely wife Erin. Keep up the great work.

[@nowornever_aus]

Thank you so much!

[@youlross6544]

Well done looking good

[@nowornever_aus]

Thank you!

[@nowornever_aus]

Cheers!

[@christophergear7247]

You can get your metal bent at a sheet metal shop. Just take a template of the curve and they can bend it. Keep up the good work. Chris from Western Australia.

[@davetunbridge6637]

Beat me to it🥸any sheetie shop will bend roll and cut to what ever you need, provided they have the requisite gear.

[@nowornever_aus]

Cheers!

[@securedsystems9407]

A message to Erin That process that you took us through is a true and reliable way of not going too far and causing too much damage the way a true handyman goes through the think process your in good hands. He knows that he can achieve anything he sets his mind to.

[@nowornever_aus]

Thank you ☺️

[@davidbonfield429]

When installing your diesel heater, mount the pump with an exhaust rubber to isolate the pulsing of the pump from the chassis. Makes it much quieter and far less annoying.

[@nowornever_aus]

Thank you! Great tip 👍🏻

[@michaelobst1830]

Looks awesome guys 👌

[@nowornever_aus]

Thank you!

[@nowornever_aus]

Thanks!

[@takingwandaoutyonda]

Alex you can build my next dream home, Erin can be the project manager ~ perfect team 😂

[@nowornever_aus]

😁🙌🏼🛠️

[@cindywhalley3370]

Looking good guys, love the new shape ❤

[@nowornever_aus]

Thank you!

[@paulhardie6796]

Hi just a suggestion if you haven’t already thought of it You can get checkerplate folded at sheet metal place. Just do a template for it. Looking good all the best

[@nowornever_aus]

Thanks!

[@JonLucas-lk2gj]

Alex, Top Job.Thats all I got.

[@nowornever_aus]

Cheers 🙌🏼

[@lyndoncarter1528]

Looks much better

[@nowornever_aus]

😁🙌🏼

[@_Rikki_]

Looks so much better and if you look at all the new caravans they have all gone flat fronts like that aswell

[@nowornever_aus]

Thanks!

[@rossjohnston-tq2cr]

You are doing the right thing. My last three vans had Front boots and they all leaked because of the angle of the doors

[@nrd6386]

They leak from not being sealed correctly! Has nothijng to do with the angle of the doors.

[@nowornever_aus]

Cheers!

[@twocoddiwompletravellers]

I think it looks better with a straight front Alex.

[@alisonphilp7497]

Thanks for another episode guys love ur work keen to see the final product

[@michaelshaw3890]

Looking good guys. Reckon that was the best way to go. Rather than cut the old floor out .. if it’s not to bad just lay some 10mm marine play over the top of the tin and seal in well. Still put drain holes in. Just a thought.

[@nowornever_aus]

Thank you!

[@nowornever_aus]

Thanks!

[@robswann2561]

Can't wait to see how it turns out. Love the new shape - transforms the appearance and modernizes the overall look. Great vids guys - love your work, really do

[@nowornever_aus]

Thank you so much!

[@jonnythunder92]

All the cutting vertical makes sense now you have done it....I did post another comment asking why you are doing that but deleted as now it all makes sense. well done.

[@nowornever_aus]

Yes I agree it sounds strange to do but just seems to work, cheers!

[@Adam-ox6zy]

I’ve just replaced the front of our van with checker plate and it has the same angles yours did. It wasn’t too hard to get the bends right and nice with a rubber mallet and a couple of round logs and some patience… but I’m kinda wishing I did what you did. Looks better as the curves are kinda old looking now these days. Plus going straight down gives you more draw bar to play with. And I love the twin door/hatches idea too coz our electrics are buried behind the front on the left same as yours. Loving this Reno! Sub from me 👍

[@nowornever_aus]

Thanks mate!

[@63holden]

Kicking goals guys 😊

[@nowornever_aus]

Thank you 🙌🏼

[@mflashtravel6824]

Doing the vertical cut on the front makes sense as stated easier to work with the checker plate, but also vertical front will allow for tool box to be set back further, therefore weight moves back further, therefore less on towball. It makes sense 👍

[@nowornever_aus]

Cheers!

[@CharlieSammut-g9q]

To take the cover plugs of the tail lights use blue tack. Place some on cover plugs & with a quick action pull off.

[@nowornever_aus]

Thanks!

[@treeman3663]

You can add more insulation as well at the back

[@nowornever_aus]

Yes that’s on the cards for sure

[@marnibarratt8805]

CMON ERIN!! its shit loads better baby!🤩

[@nowornever_aus]

😁

[@iansharpe5306]

A good tradie can give you what u want

[@HudyGamer14]

Do a square front and use a tool box that is full width, with gas bottles in the middle. That way it keeps drawbar neat and tidy

[@nowornever_aus]

That would look great!

[@aussiefarmer6012]

With tapered top and corners for aerodynamics.

[@denniscalvert3390]

Good job, liking the square font look. I just found that my 16-foot van is actually 18-foot base on the way you measure a caravan which agrees with google. Hmmm, they must measure New Age caravans internally.

[@nowornever_aus]

Thanks! Yes unfortunately it’s not a universal measuring system so some are different

[@kevinryan7649]

I recon you nailed the front mate

[@nowornever_aus]

Thanks!

[@deanbarber6635]

It's really great to watch, guys. Good time to chuck on a bike rack if needed! I have subscribed and am looking forward to more content.

[@nowornever_aus]

Thank you!

[@WarrenRorison-yb5ux]

Hi Alex and Erin I really like the look of the New front end gives it a retro look and modern update. Have a hard think about doing the same too the rear end, would make it easier for you and side on and 45 deg look so even and flashy update to the old girl . Its o.k. Erin have faith lolooo 🤣😅😆 Go Alex

[@nowornever_aus]

I think we are actually going to go that way for that very reason. Thanks mate!

[@judithtaylor6916]

Who's that new guy under the van? Oh Alex with his new hair cut! We have to regularly apply surface spray to the van wheels and stabiliser legs to stop the ants crawling up into the van when its not being used.

[@nowornever_aus]

😁

[@peterwinter449]

Hi guys your doing a great job , i like the modern touch with the square front end , if you haven’t got your J Mould yet I use Action aluminium for new J mould ,

[@nowornever_aus]

Thanks! We don’t yet so I’ll check them out 👍🏻

[@damiant5876]

Love the look of it with the square front. I reckon you should have taken it further back. Have you considered the size of your front toolbox? You'll need clearance for your boot access doors and still want a decent sized toolbox for something like the BBQ.

[@nowornever_aus]

Thanks! Wanted to leaving a descent amount of room for the battery system/ storage Not sure what toolbox yet but will most likely just work it around how the doors end up working

[@adamwilliams9695]

Looks heaps better with the square end, you could but a toolbox on the front with an outside kitchen area and storage on other end

[@nowornever_aus]

Thanks! So many options now!

[@filthyoffroadadventures]

Glad you didn’t chicken out looks great now. Interested to see how you do the rear curve since it’s so tight think it will bloody hard.

[@nowornever_aus]

Cheers guys!

[@tonystama1227]

You might be able to use the honey comb floor material for the underside of the battery floor

[@nowornever_aus]

Would love to have that for the whole van!

[@thenuttybunchtravellingaus]

That front shape is heaps better guys. Just remember now she is a once of a kind

[@nowornever_aus]

Thanks! Yep she sure is!

[@aliebenberg6668]

Like the front shape - good call! To give flexibility to the front area and how you use it, why not put a side access hatch next to the awning? Might help load in chairs etc? Could hinge a shelf in there also that can be latched upright on back wall? ….so you can load lighter items from top onto shelf when down and then seperate from heavier items in bottom. Allow you to remove the bottom items whilst leaving the top in. Having a hinged shelf means you can latch it back and then just load up the space as one if you want to put in bigger items from top etc.

[@nowornever_aus]

Thanks! Great ideas!

[@bencole9936]

Ive a water leak same corner Heavy rain won't leak, light rain or washing will leak I gave up on it Watching you do this makes me thankful my OCD didn't take me down the same path 😂

[@nowornever_aus]

That’s a bugger!

[@peterryan7340]

Replace that timber cross brace with aluminium box. No water damage in the future

[@johnmathisen1167]

Alex I recon that the rust in the front boot is from the old battery, any battery acid even a small drop will kill a metal surface even galvanised

[@nowornever_aus]

Yes I think you’re right!

[@Spad562]

Square front end looks the goods. Maybe carry the chequer plate all the way under and delete the timber.

[@nowornever_aus]

Thank you!

[@jasonwishart6800]

a tool box on the a-frame is well worth having

[@nowornever_aus]

👌🏼

[@fleurneumann8430]

Loved your episode especially your banter between you both kept us amused . We assume you are having a tool box on the draw bar so therefore cupboard doors will be above the toolbox and you want the cupboards doors vertical ……….so does that mean a low profile toolbox ? Will look forward with anticipation to next week’s episode .

[@nowornever_aus]

Yes it will have to be a low profile box, not 100% it will even work yet so we’ll see how it goes!

[@Elizabeth-k5u2v]

The square front is more up to date as most vans have now

[@nowornever_aus]

I agree

[@sharynnollnoll5795]

Make sure you have enough access at the front big enough to access your battery system

[@nowornever_aus]

Definitely will 👍🏻

[@ianpyman5003]

Alex, instead of using meranti, try kiln dried Canadian Spruce, brilliant timber. Check Andrew from Winjana 5th Wheelers in Toowoomba, they use a lot of it. Good luck.

[@nowornever_aus]

Thanks!

[@ab7406]

Would be investigating around wheel arches to bottom side walls

[@treeman3663]

Get Erin to look at Bryce and chelsies new van with a flat front

[@nowornever_aus]

Will do, it looks great!

[@_bodgie]

My guess is the rust is from the old lead/acid battery. I reckon it'll look good once you're done and you should be able to find some more suitable boot doors that'll make life easier too.

[@nowornever_aus]

Thanks! Can’t wait to see how it turns out!

[@kevintaylor5633]

If you have to replace your tail lights, a great idea is to add reversing lights so people know when you're reversing, it might save a life.

[@nowornever_aus]

That is a really good idea!

[@herefishyfishy7373]

Go side hatches, the front hatches may get in the way of installing the big toll box😊

[@johncrossling8845]

Sorry Alex/Erin I'm a bit late to the party in watching this episode. Those rear lights are called jumbos, go to your local truck dealership and they should have them on the shelf for approx $200 each. They will be LED and last for ages Keep up the good work and the videos coming Cheers

[@nowornever_aus]

No worries! Thanks so much for the info!

[@DeneOLoughlin-ek9ee]

Good skills. Is it worth applying a wood preservative like Everdure or a thinned epoxy resin to the exposed timber before sealing up? Meranti just has to look at moisture and it rots.

[@nowornever_aus]

Yeah definitely worth it

[@jo_clarke1960]

"It'll be lighter as we're cutting all this off", "it will be checker plate from here on down", from my days in manufacturing, I'm pretty sure checker weighs more 😁 and Alex whatever you were taking, either stop or learn to share please 🙏. Without rollers, flat will be easier as you won't stand a chance of getting on the road for ages trying to handwork that amount of checker. You pair are nuts, great vids and many laughs 👍

[@nowornever_aus]

😂 thanks mate!

[@robertarmbruster5650]

All the bottom side rails rot as well because they are exposed, so another 600mm high checker plate along the sides will balance it out and look really good. I have just come home from the Brisbane Caravan and Camping Expo Supershow or whatever they call it and unbelieveably there are still people out there manufactureing vans just like yours is built.

[@nowornever_aus]

It’s definitely something we’ve considered but just a bit worried about adding extra weight!

[@Brennomac83]

A sheet metal place will bend and roll anything for you.

[@georgewinters3191]

@Brennomac83 Was going to make the same comment, I would create a new front panel with tabs to be able to join onto the existing metal. That way he could remove the floor bit and put new timber then lay the new metal part box in , seal it up

[@nowornever_aus]

Cheers!

[@neillee3776]

He is right

[@ronevans1574]

Maybe wiring for front spotlights while you have the chance

[@nowornever_aus]

Definitely upgrading some lighting!

[@Bradp72]

Mate any local sheetmetal shop with a long enough roller could have done what you needed so you didnt have to cut the front.... i'm a sheety.....just not in qld

[@nowornever_aus]

Yeah I know it could be don’t but very happy with the square front!

[@LeonieHall-c4o]

Could get your rear checkerplate bent up at an engineering or fabrication shop. They'll do it nicely yes?.

[@nowornever_aus]

Yes I’ll be looking into having that done, cheers!

[@greggenge481]

Looks better straight. Question: With checker plate for front and rear - are you doing the sides as well. Also consider the weight which no doubt you have. These are really good vids as has your previous ones. Please keep them coming. Happy travels.

[@nowornever_aus]

Thank you! Yes that was considered but think it’s too risky with the weights

[@thevettes_]

Hey guys, have the considered a side access similar to a jayco silver line? Might give more useable space on the door side of the van Great video guys! Keep them coming

[@nowornever_aus]

Thanks guys! Yes we have considered that but think it will be a little too tight on the battery system side

[@WarrenRorison-yb5ux]

Hi again looking at the frnt floor under boot ,if you were to cut floor back leaving boot skin in and incorporating the new floor with a stronger under frame to match up to the front of the van too assist with attaching New checker plate????

[@nowornever_aus]

That would work well 👍🏻

[@WarrenRorison-yb5ux]

@nowornever_aus hi Alex 👋 Thanks for your reply, appreciate it 🙏 👍 😀 good luck it'll look unreal

[@Onedaylapper]

I love how you both can laugh through the whole process! My hubby and I would end up in divorce court if we attempted something like that 😂 Will you need to get new mod plates for new length and weights?

[@nowornever_aus]

Thanks! Not sure in that yet!

[@treeman3663]

Loving the longer videos 📹

[@nowornever_aus]

Cheers!

[@paulholtham9945]

So where can you source the trim that covers around all the joins of the sheets front back and sided.

[@nowornever_aus]

Most aluminium suppliers

[@tombarnes9267]

Looks good. How does the modification impact your insurance?

[@nowornever_aus]

Not sure to be honest, will have to sort that out once we are done

[@Brad.whatthe]

Trace and cut a template of the curve and find any sheet metal shop and they will roll it for you and probably get the materials cheaper than you can, jus sayin

[@nowornever_aus]

Thank you

[@just_dave]

Now I want to cut the front off my caravan 🧐🤔 love the content

[@nowornever_aus]

Do it! Cheers!

[@jayedavies3686]

The rust is on the top and has eaten through the galvanised metal. From where the hole is in the metal is where the acid was most concentrated

[@nowornever_aus]

Good to know, thanks!

[@Whenandwherenext]

Archie’s took a pair to the cape and only broke 2 months ago 3 years old

[@MareeForman]

Great episode Lookin good. I am a lot like you Erin so understand where you are coming from but Alex is very competent. Good luck with the rest of it. 👍👍

[@nowornever_aus]

Thank you!

[@rogerread3452]

yep - remove the lower metail section as it will give you access to the whole floor to replace - you have gone this far now - do it once, do it right....... - again your all over it mate. well done

[@nowornever_aus]

Thanks!

[@davekerr8133]

I cant believe the crsp insulation in thd walls. There will be so much thermal leakage through those walls.

[@nowornever_aus]

Yeah I know, not cut to size at all

[@garryhern2908]

I would clean it all up and replace the alminuim sheet with checker plate and don’t bend or roll it yourself.any desent sheet shop can supply this as a perfect fit.

[@nowornever_aus]

Thanks 👍🏻

[@gilesy7169]

Jeez mate you seem to know what you’re doing, did you use to build caravans or something???😉

[@nowornever_aus]

Yes but I have no idea how you would know that! …….😏

[@theadmiral7726]

Just remember that the rear number plate cant be higher than 1.32mtr, this to comply with number plate recognition, its hefty fine if you get pulled over

[@nowornever_aus]

Yes we’ll have to look into that

[@slowboat6021]

surely there is a sheetmetal shop nearby who could roll and fold you checker plate?

[@nowornever_aus]

Yeah for sure we just hadn’t found anyone at that stage 👍🏻

[@ElarMack-ci1of]

Oh dear, giving instructions to a lady who doesn't know what Tin Snips are or side cutters either. The easy part is fixing the van, it seems the hard part is procurement of the gear. Having an assistant who isn't. is frustrating.

[@patryanlrd666]

Unless you’re really short that number plate looks above 1300mm. 🚓

[@nowornever_aus]

Well we are really short but I’ll definitely check that 😂

[@norego6237]

yea the batteries over charging leaking acid rusted out that galvanized steel floor, the rest of it looks too good

[@nowornever_aus]

Thought that might be the case

[@RalphWaite-e8s]

Looks like acid damage

[@phillip9468]

Square front = wind resistance = fuel consumption. 🤔.

[@nowornever_aus]

Time will tell, my theory is the flat part is directly behind the car so it shouldn’t make too much of a difference but I’m no expert!

[@racheldorrington2258]

When you hand a tool to someone make shure you hand them the handle not the super sharp cutting edge or you will have to become a nurse.

[@nowornever_aus]

She’ll get there, first days as a TA 😂

[@mindyedwards2699]

When you put the tow bar back on, will you be sealing up the open ends so that you don't get sand snakes in there? and would it look better if powdered coated black make it a bit more modern, you could do the front to match too?

[@nowornever_aus]

Probably won’t close it off but definitely looking at painting it 👍🏻

[@TerryCassar]

Instead of doors on the front, why don’t you put tall access hatches on the side of boot

[@nowornever_aus]

We did consider it but the way they battery system is layer out doesn’t leave enough room to do so