Hot water

A Suburban SW6DEA direct ignition, gas and 240V electric 22 Litre hot water heater was sourced and fitted as pictured to reside alongside the bathroom module and under the fridge.

Electrics

A 15A 240V feed has been wired into the vehicle via an RCD and VSD initially supplying power to an internal dual pole power point as well as the Ibis 3 AC unit.

Water tanks

Three 70L tanks were sourced from Hugo at Custom Coaster Conversions  - two for fresh water and the other for grey water.
The fresh water tanks were fitted behind the rear wheels on both sides of the vehicle and the grey water tank for ward of the passenger side rear wheel.
The tanks were fitted using a 30x30x3mm galvanised angle hanging bracket with two 50x3mm alloy straps underneath.

Upholstery

Panels were re-upholstered with Capliner Platinum fine carpet like material from Southern Cross Textiles. Sika spray contact adhesive was used on both surfaces before joining once tacky.

Wrap

We decided to wrap the Coaster to protect the bodywork during our planned travels. After spending numerous hours learning the process on Youtube, we decided to try it ourselves.
We sourced some Avery Supreme Wrapping film and started stretching and applying film on the body!

Before

After

Windows - Blackout

The Coaster needed major work on it's windows with a cracked/deteriorated tint needing replacing as well as cracked, dried out and shrunk rubber sash seals needing replacing.
Late model sash windows were sourced locally with good condition tint and rubber seals and with the  nicer black frames. Non hardening butyl sealant was also sourced.

Removing the windows is actually pretty straight forward - remove the pinch weld trim, remove the U shaped retaining clips and insert a wedge between the window frame and pinchweld to stretch and the butyl sealant and cut it with a sharp knife to allow the window assembly to come away from the body. Fitting involves remove the old sticky sealant, clean and apply a new bead of butyl sealant before attaching the window assembly ans securing it with the retaining clips and covering with the pinchweld trim.

The driver and front passenger window frames were removed, dissasembled, cleaned, primed and painted black to match the sash windows. The rubber seals were replaced/repaired and then the assembly was refitted.

The rearmost and front most windows were tinted to match the pre-tinted sash windows for a consistent look.

Before

After

Air Conditioning

A frame was need to be manufactured to attach to the roof to support the heavy Aircommand Ibis 3 air conditioning unit

After careful measuring, 40mm alloy square section, 40mm alloy angle sections and 4.8mm steel rivets were used to construct a H frame to tie into the existing roof bracing structure and bonded with Sikaflex to the roof skin.

Gutted

First things first, seats were removed, rear heaters were removed and bolt holes holes plugged up to allow it to be re-engineered for driving on a 1A license in NSW.  GVM was adjusted to 4495kg.