Build Photos

Chassis Delivery

The Volvo chassis was delivered to us here in Vancouver at the end of February, 2015. The next day we set off to deliver the truck to the body builder in the U.S. The drive was sunny, but cold, until we reached the lower states. There the snow started falling and the rest of the way was on slick roads. We arrived safely after a three day drive. These are our photos from the trip.

Picking up our truck from Volvo.

The full chassis looks longer than we needed. But it's just an illusion.

Halfway to the builder. We drove day and night to get the truck there as soon as possible.

The truck was a sloppy mess when we arrived.

The back wheels on one side were driven up on blocks.

Before we could take the chassis to the drive train specialist for the front drive axle, the builder needed to determine the amount of twist in the chassis.

Wall Panels and Box Construction

By the time we delivered the chassis, the box had already been assembled. But the builder did send photos from before the assembly. Some of the photos are from the builder, the rest are our own.

This is a look at the cross section of our wall material.

Slots were routed into the floor for radiant floor heating tubes.

The edges of the floor were machined to accept a similar edge machined on the walls.

The floor heat is diffused using an aluminum mesh that wraps tightly around the bottom of the heating tubes. It was far less effective than what we hoped for.

A look down the drivers side from the back.

The edge angle corner joints are covered with a three sided aluminum cap.

The outside of the box is ready for filling around the edge angle, and then its ready for paint.

On the transport trailer for delivery to the paint shop.

Initial priming of the edge angles.

All primed and ready for colour coat.

Paint job all done.

Ready to head back to the builder.

Read about builder fraud here

Truck Cab Modification and Box Mounting

The only change that needed to be done to the truck cab was that of cutting in the access door to the camper section. A brake shape had to be welded on for the sealing boot, and then everything painted to match the cab colour. Photos are from the builder.

The location for the access tunnel marked on the inside of the truck cab.

The cutout location as seen from the outside.

The tunnel seal framework all finished on the cab.

A look down the length of the chassis showing all the hoses for the hydraulic front drive axle.

The steel subframe that the box will sit on. It sits here upside down.

The box with some windows in, sitting on stands waiting to be placed on the subframe.

The box strapped to a forklift while the truck is backed underneath of it.

Almost in position to lower onto the subframe.

The plastic shield for the tunnel seal to rub on can be seen here on the front of the box.

The box is fully mounted, and only sticks our about 5" on either side of the cab.

Technical Equipment

These are shots of the Mastervolt electrical equipment, and other technical gear during the installation phase. It also shows some of the hydronic heating equipment and plumbing. Some photos are from the builder, and the rest are our own.

The plumbing wall before it is installed in the truck.

A hole drilled through the 4" thick wood floor for the hydronic plumbing lines.

The plumbing wall installed with some electrical equipment attached on the passenger side.

The hydronic domestic hot water heater. It can also be plugged into 110 volts if needed.

From left to right, the wifi hub, then the solar charge controller, then the white generator transfer switch, and finally the world charger.

Four 5000 watt hour, 360 amp hour lithium batteries.

Two Mass Combi 12/4000 watt inverter chargers.

The finished rear electrical wall.

A look up to the bed area. That will get finished when the deck is installed above the utilities/storage bay.

The finished plumbing wall with the protective screen.

The outside patch panel where water hoses and shore power is attached.

The driver side Webasto boiler initial installation.

The subframe mount for the motorcycle lift between the underside of the box and the top of the underneath storage box.

This shows the right fuel tank, and the difficult to access fuel filler neck.

The escape hatch, air conditioners and roof vents.

The six solar panels all installed on the roof.

Laminate Cabinetry

This is my design drawing of the TV, control and camera storage cabinet.

Our cabinetry was all custom made to our requirements. The most complicated of the cabinets was the control/camera storage cabinet. With this one piece, nothing was left to chance. I didn't want someone else, particularly one that can't draw to save their life, trying to design and draw an item that had such a specific purpose. So I provided them with a detailed drawing of exactly what we wanted.

Here is all the cabinetry staged and waiting for installation. Photos are from the builder.

Kitchen sink cabinet.

The laundry cabinet (far left) and the camera cabinet.

Closeup of the laundry cabinet. It has storage cupboards above.

The camera and electrical control cabinet.

Pre-installing some of the electrical components.

A closeup of the control panel.

Kitchen counter cabinet, and the side that faces the entrance stairs.

The back of the cabinets with the primer on them. They are glued to the walls and ceiling.

Interior Construction and Cabinet installation.

These are photos the builder sent us during the interior wall and cabinetry installation.

Looking into the bed area. The two short walls are where the water tanks go.

The emergency escape hatch on the ceiling, and the black primer on the walls for gluing the cabinets to.

The bathroom and shower walls installed, and the radiant floor heat tubes in the floor.

Looking inside the shower to see the moulded floor pan.

The beginning of pulling wire.

The ceiling cabinets and bedside cabinet all installed.

The front living quarters in full assembly.

Wires sticking out of the control cabinet.

The control and camera storage cabinet with the doors open. They had to be bifold to fit in.

The left side cabinetry. Coffee cabinet, fridge compartment and laundry cabinet.

The tunnel door installed.

Cabinetry all finished with the doors all installed.

Looking aft to see the counter cabinets in, and the floor heat tubes in the floor.

The kitchen counter with sink and faucets installed.

The kitchen sink with tacky drinking water faucet on the left, and over sized main faucet.

The coffee machine cabinet with LED light underneath it.

Laundry and fridge cabinet with utilities poking out.

The coffee counter is well lit by the LED light.

The marine fridge/freezer is installed.

Another set of cabinets finished.

Stainless steel lining in the entry step area.

The dinette cabinetry base, with the cheap and unstable table pedestal.

Gluing the bathroom cabinets in place using braces to the forward wall to hold them in place.

Cabinets and countertop installed.

The bathroom counter and sink. Too bad they don't know about the very common practice of bulging the cabinet so the sink can be centred front to back. This is very unprofessional.

High quality toilet is finished.

The steps to get up on the bed.

The bed area with a window shade and door fronts. The back wall get upholstered panels.