Black Kombi Day Van Build

[CooseVW]

There's also a leisure battery setup under the passenger seat but it's been disconnected in the engine bay. Bit of digging will see that right!

Update: Six weeks and a healthy dent in my savings later, we have power!

I was determined to keep this install "invisible." In a compact day van, that meant getting creative with the under-seat space. I fabricated custom brackets to fit the entire system—battery, charger, inverter, and consumer unit—under the front seats.

I can still pull the battery or operate the isolators without having to bolt/unbolt the seats. Here is the bracketry mounted via rivnuts into the existing factory holes.



I also had to DIY a compact "multi-connector" (a busbar, I think?) out of some brass bar stock. Since exposed brass, curious children fingers and plenty of grounding don't mix, I 3D modelled and printed an insulated cover for it to keep the sparks & electric shocks at bay.




Then came the fun task of routing the wires. I used flexible conduit to snake everything from the seat bases, up the B-pillar (hidden behind the trim), and over to the "non-sliding door" panel. My fuse box and switch panel are tucked away there, so it works well as a hidden distribution hub for the whole setup.




The "distribution hub" on the back of this panel got a bit out of hand as the "while-I'm-at-it" bug hit hard! Here’s what’s in there:

I’ve got the roof and tailgate LEDs wired to a relay so they trigger with the doors (OEM style) but run off the leisure battery. I added a parallel switch for manual "camping mode" and even a soft-start module because I couldn't stand the cab lights fading on while the rears just blasted on.

I also tackled the inverter remote on feature—used a relay there as the inverter is looking for a dry contact but needed 12V for the switch LED to glow when it's on.

For the rest, I’ve got a few USBs a 12V socket for the Slidepod, and a Renogy battery monitor.

My favourite part is the "WAGO Marshalling Rail." It's basically a distribution block for the van; every outgoing cable plugs in there, so the whole panel comes out easily if I need to tweak (or more likely, fix) anything. The fuse box is tucked into its own inspection hatch which I boxed out with MDF.





Still a bit of a work in progress—I’ve currently got the acoustic headlining in pieces—but I just thought I'd show the progress. Here is how it’s looking...





I'll stick some more photos in when I'm all finished.

 

[ChestnutBrown]

Looks superb. Fair play.

 

[Skyliner33]

Nice work

 

[CooseVW]

So it's finally all back together and clean!

I'm really liking what I'm calling the 'utilitarian chic' look. Everything I've done suits what my family need from the van. Even down to the 4 folding coat hooks for hanging wet coats on after a morning fossil hunting with the kids .

Here's the finished photos...




Obviously need to put the 2+1 seats back in but they currently out getting a good clean!

 

[CooseVW]

I've been working on a replacement for my slide pod... It is too big of a thing for me to store when I'm not using it, which is about 99% of the time .

Shameless plug - it's up for sale in the for sale section...

I liked the look of the 'Infinity slot together kombi bed' but I figured I could do better.



My idea was to make a slot together bed, which slotted together and was mounted to the tie down points with thumb screws. But the kicker - it all folds down into its self and it can be carried like a suitcase and stored very compactly.

Anyway, I've 3D modelled it, and I believe I can make it work.




My next step is creating the MDF templates to use when routing out the ply.

I've had to make a few custom router jigs, which once again have been 3D modelled and then 3D printed.

Anyway, here's some work in progress photos.... I'll keep you updated if/ when I get it finished .











I've based it all around the 'forty winks' folding mattress size so I don't have to custom make that too .

 

[CooseVW]

Finally got all the MDF templates finished and the 18mm softwood ply cut to size.

Need to find a few hours where the kids can't bother me to get them all finally routed out.

 

[CooseVW]

Making some real headway on the slot-together bed...

Here’s a bit of a photo dump to show the progress. I’ve survived everything from sunburn to trench foot thanks to this wild weather, but I’ve managed to squeeze in an hour here and there either in the blistering sun or under a gazebo in the pissing down rain. The main frame is officially done—now I just need to route the bed boards and I’m on the home stretch.

I've succumbed to the fact that to make this functional, I'm going to need 4 thumb screws, two to hold the front panel on, and 2 to hold the side supports down the the rear board which will be fixed to the middle tie down points in the van.

 

[CooseVW]

I got distracted by a folding table I saw online...

Campervan Table and Rail Set for Volkswagen Kombi T5 T6 T6.1

VW Kombi table and Mito Sliding Rail Set. Removable table designed to fit in front of the seats, to provide leisure space for entertainment, eating and working.

www.vangear.co.uk

I figured I could give it a shot myself rather than spend much less buying something off the shelf . By custom making it I had the added bonus of having the opportunity to made side it down the side of the rear bench on the rail when not in use, as opposed to removing it and stowingnit away. Added surprise bonus - it can cover the switch panel LEDS when camping so they aren't too bright when sleeping in the van.
Armed with my new 3D printer and my below average 3D modelling skills, I figured I could buy a generic folding table leg from eBay and make the rest myself.

The leg needs to be longer than the depth of the table (which is restricted by the height of the door card if that makes sense) which doesn't lend its self to the table leg being folded flat and the table folded down. So I set about making a hinge for the leg.

Then I removed two of the panel clips and fitted an M6 robot in their place to allow the custom brackets for the rail (13mm stainless round bar) to securely mount into.

Add to this some bolts with heads had to turn down in my battery drill to make clearance for the leg to fold, and some custom table hinges to fit the 13mm rail and it's good to go .