I've had a few threads here and the advice I received was magnificent. I adopted most of it to improve my build and make it safer.
Briefly, the van was to weigh about 220 kgms tare, be 10'8" long, 6'2" wide and 7'8" tall from the ground. It was very ambitious. I haven't got to the weighbridge yet but I anticipate around 330 kgms.
Towball weight was the big worry. How do you know the van you are building will weigh your projected weight on the ball? You don't, you hope. In this case if the towball weight (max 25 kgms) was heavier than that say 40kgms then weight would be needed to be added to the rear. Imagine doing that? It would likely have meant adding say 30 kgms to the rear to lessen the ball weight from 40 to 25 kgms. With this in mind I deliberately located the axle 20mm less from the axle to the rear of the van compared to the axle to the front of the van body. ADR';s clearly stipulate that the front distance cannot be less than the rear. So ok there.
During the latter part of the build two items at the rear half of the van caused issues weight wise. The acrylic shower wall and the door. The original door was purchased from
Canberra off a Robin pop top and was 1420mm high. This caused too much bending of my neck and upper back to make me comfortable and I had nightmares of hacking the top panel out to place a taller one in. So the move was to buy a new full height door and that was a good move but it weighed 17 kgms up from 8 kgms.
It all made for a tail heavy van but alas, a long tool chest sitting in my shed was the answer. It fitted on the drawbar and left enough room for the turning of the rig. Inside the box is a 100AH battery and a small table top BBQ and room for tools. End result is- towball weight of 8 kgms. Then there is table and two captains chairs to go under the beds forward of the axle. The Waeco CF-18 fridge and
water tank are rear of the axle but only just. I think the spare wheel should go under the front of the drawbar. 8 kgms there would be good.
This is the first and only van I'll build. What lessens did I learn?
Well, the axle could have gone 50mm further towards the rear in hindsight, I should have fitted brakes and will do so in the near future (my previous rig a Detour motorcycle camper had the same size 10" wheels and it had magnetic brakes and were terrific), I would order the roof sheets 70mm wider than the walls (I ordered them 30mm wider than the walls but any slight out of square frame causes issues).
Good decisions include-
6mm marine ply floors with 13x13x1.8mm tube joists spaced 160mm apart works
well and is strong enough for my 125 kgms weight.
13x13x1.8 steel tube frame was good. Very strong when welded as a cage.
toilet and shower tray was the best decision for comfort and convenience
lightweight ceiling carpet from Bunnings at 300 grams/sq metre.
10" wheels and tyres are 9 kgms less each compared to 13"
The 50x25x3mm drawbar with 3 trusses works really
well. So strong
and plastic drawers for the kitchen with acrylic sink...all good.
Solar camping hot water bag for a shower with cold water only from the tank proved itself in out previous set up so we stayed with it.
The "foldaway" antenna and booster at around $250 was worth the money.
large square hatch for ease of portapotti service (dreaded lifting it and stumbling down
the steps)
Edging was black with white insert. Think this sets the van off nicely.
Anti Sway friction type bar has been purchased...on its way.
Eyelets at the peak of the van for tying the van down in gusty windy conditions.
I'm dreading the installation of the ceiling carpet but it has to be done.
Again thanks to all that helped me along the way.