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Tom, sorry for delay we have been away and as usual out of connectivity most of the time and usually too knackered whilst out walking or cycling and at the top of a hill to browse….it’s the extra years you know!
My sky light ( which is original) always held well off the roof whilst the inner sat on the seal. I have just measured the outer with the inner sealed closed and the gap is 20mm.
This may well be slightly more than original, but only 2-3 MM because the last time I did the ‘dropped inner leaf’ I doubled up on the thick adhesive strip – (from supplier suggested by Maldwyn.
Thanks for a great post and information Tom. The roof light seems a scary project but it’s not so daunting now. A super quick job Tom, well done – you deserve that drink.
Regarding sealing the outer frame:
Firstly those Star washers had to come off so that I could remove the sky light for good access. I found that a some of screws were up to a 1/4 turn loose so I applied the Hodgesons Seamseal CV around the edge and worked it in – then tightened the screws.
I then applied a generous bead all around everything and smoothed it out – it’s very visible but neat, at that time I wasn’t up for removing the frame if I could resolve the issue easily. It’s so easy to work and not too messy.
I was up cleaning and polishing the roof last week from my scaffold tower and it still looks good and thankfully doesn’t leak.
Good to hear from you again Tom, what a big hello and sorry to see your problem.
Excuse the pun, but what another cracking ‘how to do it from you’
It was a relief to see the price that you had secured as I always imagined a lot more.
Tom when my skylight leaked from around the seal ( frame meets roof) – I used Hodgesons Seemseal CV, it’s very easy to use and I had read that it is excellent for bedding in Windows etc as it does not set.
I have just washed/ polished my roof using my scaffolding tower and the sealant still looks good and has remained leakproof.
Thanks for another helpful and informative post and best wishes for some decent weather and a straightforward re-assembly.
I have only seen more in an Exsis when we loaded Up Barry’s van for a photo shot at an Exsistravaganza – 23 people I think!
We do come close when we go off on our annual camping trip with our son and his wife when he returns fron Qatar each summer. Four adults, 2 folding bikes, 1 Di Blasi folding trike,1 mountain bike (front wheel removed) and 2 extra picnic chairs- it’s an obstacle course to move around. And then in the boot the picnic table, Cadac BBQ & 907 Camping Gaz cylinder, picnic table & 2 chairs, the porch awning & poles.
It all has to come out before we can do a thing and has been the source of astonishment several times to fellow campers that so much can come out of such a little van. No competition the Exsis space and storage is the best.
Hi Katy & Alistair – thought that I would check out the Fiat forum for you, but found that you have already explored that avenue and have had a good lead, so I am hoping it works out for you.
At times like these we need all the leads that we can get, get lucky.
The wire that I used was Constantan wire from Maplins with resistance @ 4.2 ohms/metered .
Maplins are no longer trading, but I expect that Constantan can easily be sourced.
I have also found all my original formulae / calculations and notes of how I did it…..
At that time the easy alternative was …. Whilst many 230v reduced to 12v through transformers could be found, I could only find one 12v DC available (lightingstyles.co.uk) and that was approx £44 +P&P, which seemed expensive compared to regular ones.
An extract from my notes at the time shows the cost
“Make it yourself, Fred”, he said. Barry went on to explain an experiment that he had done many years ago to make a heater for a motorcycle jacket – he used ‘Constantan’ wire and passed me the link to Maplins.
So that is what I have done and it works brilliantly, using components sourced from Maplins & Halfords (next door to each other in Bath). The wire cost £7.99 (got miles of it left over) + Maplin 10 amp Illuminated (green) 12v Rocker Switch £1.99 + Fuse Holder & Fuse and some joiners/spades etc from Halfords just over £7 = £17.25. You can get waterproof switches, but I liked the look of this one.
Chris, you have made some great mods on your van and proving to be a great asset to the Exsis Owners Forum, thanks.
Many years ago, Robin from Chippenham who probably does not have his Exsis now as we never hear from him, made his own version by using computer fans (easily available ) housed in a funnel, but I see that you used a SOG unit.
Whist you have the basin/mirror off, which is quite a straightforward job following the ‘how to and pictures ‘ posted by Barry all those years ago….why not fit a heated mirror pad behind it is brilliant on those colder mornings, I love it.
My home made effort was posted in detail on the old forum, which is now lost and I don’t think that it ever made it into the ‘Little Exsis Book’. I made my own using resistor wire after a tip off from Barry….but they were available on line at approx. £44(12v), off course my way was much cheaper. If you seriously consider taking up this tip I can look up the old photos and post them.
Nice to hear from you Ali & Ted – still doing your epic journeys then.
The contact for Derek Justice can be found in the spares/manuals section provided by Barry if that is still current Derek Justice email@example.com.
When I replaced mine I strengthened my backsplash by a different method to Barry. I used expanding spray foam having made up a cardboard former to contain the stuff – its nice and firm.
See the photo below and note that at the same time I reinforced the section where the tap fits in using UPVC weatherboard
As Barry highlighted there was discussion on awnings several years ago in the Little Exsis Book, problem is that there will now be newer varieties.
Our drive away awning (is in photos) is now about 15 years old as we kept it from our previous camper van days.
I probably only bother to use it once or twice a year now and that is if we go away using sites with family, because we may have extra bikes and chairs and are perhaps more inclined to sit in the awning as the evening draws on and gets chillier( soft southerners!).
When Gill and myself go touring we only spend a night or two in one place and the table & chairs fit in the boot and our folding bikes fit in the front of the cab with the front seats turned sideways, so we have no need to bother and we would only sit outside as long as it was comfortable anyway.
We are lucky because the smallish porch awning and separate poles will fit into the Exsis boot along with the table/chairs and small Cadiz bbq and 907 camping gaz cylinder.
I have no practical experience, but no doubt like you I have read comments on various Forums.
It would seem that negative comments can be made about the overall bulk and weight, which stands to reason as it is an all in one unit and perhaps the air beams are a little more substantial than the normal fabric.
Sorry that I can’t be more helpful specific to brands and models.
I hope that the information passed on by Barry and Travel Happy (Keith) to Ellensj was helpful. I can add a little more now so perhaps in the future new owners have a better understanding. Perhaps the problem was that the Jubilee Clip needed tightening or one of the tails had ‘popped’ out past the pin due to water/frost.
The micro switch on my kitchen sink tap has been a little troublesome for a year or so and sometimes I had to coax it into action, it finally broke on our last trip a couple of weeks ago so that coaxed me into action to replace it. By the way to get at the micro switch the tap has to be turned fully on as far as it will go and then you can just pull the handle off. If you don’t do this you will probably break the microswitch – it’s a tip I read years ago ( and I remembered Barry).
In the SG and probably the SK (different tap), the hoses have to be removed from underneath because the hole in the sink is too small to pull through the tails with the pipes still attached – so its a fiddly job for us oldies once the back of the cupboard has been removed.
First remove the two wire connectors from the microswitch noting which way round for re-assembly.
Loosen the Jubilee Clip on the pipe (hopefully the screwhead is in a forward facing position from assembly) and slide it down the pipe to clear the tail then tighten it up a little to prevent it slipping too far down. —Repeat for the other clip/pipe.
Undo the plastic lock nut from under the tap base (mine was a firm finger tight – not much room for spanners) and wriggle the nut down over the tails to remove – the tails will swivel together to help. The tap can now be lifted off from the top.
I have attached a photo below so that folk can see the tails and also in the middle the rusty looking pin in the middle. It is this pin that holds the tails in place by fitting in a groove in the tails. The pin can be pushed right through and removed. The tails can now be removed as they will easily pull out. I cleaned my pin up before putting it all back together and sprayed it with PTFE.
There is an ‘O’ Ring on each tail and ideally this should be lubricated/wetted before re-assembly ( I used PTFE spray. Make sure that the tails are fully pushed into the base of the tap when reassembling and that the pin fits properly to hold them in place.
Re-assembly is reverse order – it pays to turn the tap away a little so that when you tighten the nut as far as possible from underneath you can hold the nut and pull the tap to the correct position to firmly tighten.
I believe that ‘Mick & Patsy’ were from the Ipswich area and they were recent new Exsis owners who attended the 2015 Existravaganza.
Do those names jog your memories ?
They were not avid contributors to the old forum and not sure that I recall them on this new forum – so perhaps it’s unlikely that they will see this thread of yours
You will have to send a scouting party out – seems that you have good success with Exsis spotting!
Thanks for asking Marley.
Of course, once again thanks to Barry for supplying the solution. I have never had to change one yet and for us all it is so much easier if you know how.
Fred16th March 2019 at 08:11 in reply to: Modifying the Exsis for our Big Year Out – the techy stuff #979
Well done Chris, some well thought out mods, something to sleep on, me thinks.
I agree Katy, and I hope that Chris and Susan are enjoying better weather than us on their ‘ big trip’.
I like the Alugas refillable and the space that it creates for the extra toilet cassette. Just hope it seals well in the upright position!
Hope someone comes along soon with experience of fitting a bike rack for you.
I can understand your reluctance to drill additional holes.
can you or get a local fabricator to make a strap or box section to fit the original bottom fittings at 600mm centres, then fit the new bike rack to that using the 300mm centres.