Continuing the van conversion journey, I’ve been focusing on installing a locker above the passenger seat and setting up the shower cubicle. Here’s a step-by-step breakdown of the process, ensuring everything is secure and neatly finished.
Before installing the locker, I needed to ensure the over-cab locker and B-pillar trims were properly aligned. The locker had slight up-and-down movement and a small gap along the ceiling. To address this, I used a prop to gently push the locker upward, closing the gap without applying excessive pressure.
Next, I trimmed the B-pillar plastics to align with the existing VW trim for a flush, clean finish. Using a steel ruler and pencil, I marked the trim, cutting away just under a centimeter at the widest point with a multi-tool. I also notched out brackets to allow the trim to sit properly over the plastic. On the driver’s side, I screwed the trim in place using sharpened M6 bolts and joint connectors, pushing the trim into position and marking the back for drilling. This ensured a neat edge, especially when viewed from the swiveled driver’s seat. The passenger side was similar, using the handle’s screw holes for attachment after removing and respraying the handle.
With the B-pillars sorted, I moved to fitting the locker above the passenger seating area. I propped it in place and secured it with 4x30mm screws, adding 5mm plywood behind to maintain the ceiling gap. Additional screws connected the locker to the cab locker, and modesty blocks were screwed into the plywood wall for extra support. The locker was aligned with the aluminum trim for a level finish, taking about 10-15 minutes to install. The shower cubicle side will later be screwed in from the inside, ensuring the locker is supported along the top and both sides.
The shower cubicle required careful fitting. I trimmed the bottom of the shower side to account for roof thickness and sanded the edges to prevent damaging the suede ceiling. To assemble the cubicle, I used cam dowels and wooden dowels, gluing and tightening them to secure cross pieces along the bottom and back. The cross pieces were attached with 6mm and 5mm holes for the dowels and cam dowels, respectively. Additional cross pieces were glued and screwed for stability, particularly where the plastic curves.
For the shower tray, I added four wooden supports along the bottom edge and trimmed the sides with a multi-tool for a snug fit. A large hole was drilled in the floor for the waste pipe, using a hole saw to accommodate the larger circumference. The shower door front was pushed into place, moving the wood slightly, but this will be sealed with sealant. I also cut a notch in the top cross piece for the profile to fit properly. To ensure the cubicle is square, I checked for consistent gaps, and to prevent cracking, I plan to add a plywood piece with spray adhesive under the shower tray before final fixing.
The locker and shower cubicle are now securely installed, with careful attention to alignment and finishing for a professional look. The B-pillar trims are flush, and the locker is stable, ready for the shower cubicle to be fully integrated. This phase of the conversion has been detail-oriented but ensures a durable and visually appealing setup.
