Line Outs

If you are looking at having your vehicle lined out, you’ll find that there are various companies offering a line out service. However, what you will also find is that the prices vary drastically and that the quality varies even more drastically.

Exploria has over 10 years of experience in lining out vehicles, using a range of materials. With this experience we are able to offer a whole host of line out options, in a range of trims and styles to suit your requirements. Many customers often don’t see the difference in line outs offered by various companies, so below is what we have to offer.

Preparation

We start by removing all the factory timber panels and discard these, as the factory panelling is a thin hardboard panel which is weak and we cannot guarantee adhesion to, due to it being a painted surface. The panels also have numerous holes for the VW fixing clips, which we don’t use.

In the preparation stage, the cab is separated from the rear of the vehicle to prevent dust and dirt from entering the cab area. The floor in the rear is protected, along with any side steps and other relevant items such as rear belts are either removed or protected.

Once a vehicle is stripped out, we install all wiring required along with any additional cables & pipework such as for reversing cameras, amp housings, water pipes etc. After preparation is complete, we then sound proof and insulate, ply line, prepare for lining materials to be bonded, line with a lining material and finally finish by installing a roof lining. Each of these stages are explained in more detail on the following pages.

Camper van conversion preparation

Sound Proofing and Insulation

Once the vehicle has been wired, we soundproof and insulate the walls, doors & roof. The sound proofing and insulation is done in a two stage process, as follows:

  • A 1” thick, flame retardant, recon fiber is bonded to the inner skin of the vehicle. The material is similar to that used in many high end cars and also on the roof of the new VW Caravelle. All accessible areas are covered. It’s this recon fiber that takes away the ‘tinny’ sound & stops your vehicle sounding like a drum. It’s not the thick areas of steel that resonate noise, but in fact the thin areas; hence the importance of soundproofing the walls, roof, doors and cab headlining.
  • The remaining cavity is then filled with a recycled plastic woven product to increase the soundproofing, but primarily to improve the insulation of the vehicle.

Sound proofing and insulation gives a vast reduction in road noise and drumming, prevents build up of condensation and also makes the vehicle warmer in winter and cooler through the summer.

If you are really finicky about road noise, there are also some additional stages you can go to if you are wanting the ultimate in quiet transportation. Some of these extra stages include:

  • Dynamatting – this is similar to a tar based product, with a foil exterior which stiffens up the steel and reduces panel resonance. It’s particularly useful in difficult areas such as inside cab doors, where normal insulation can’t be used due to window mechanisms or in areas where little depth can be lost i.e. in the cab flooring and wheel arches.
  • Added dash wadding can also reduce engine and road noise especially in some basic models where dash soundproofing from factory is minimal.

Soundproof and insulate all walls, rear doors, roof and cab headlining £260 + VAT

For further info on extra soundproofing please call us to discuss your requirements.

Soundproofing before conversion Dynamatting

Ply Lining

We ply line the vehicle to our own specific templates, which are routered out on site. We use a far eastern 6mm ply wood for the sides and the roof, which is a tough and durable timber & which we can also guarantee adhesion to. The plywood is fixed in place and any joints and uneven areas are filled to leave a smooth and neat finish. All metal areas are lightly sanded to guarantee good adhesion. Once complete, all the surfaces are cleaned and then bonding of the chosen lining material may take place.

Ply lining to all walls and rear doors £210 + VAT (SWB)
                                                    £240 + VAT (LWB)

Ply lining for camper vans

Lining

The predominant material used in this process is lining carpet, although we can also line vehicles in various other materials such as alcantara, vinyl and leather amongst others. The lining material of choice needs to be carefully considered and chosen according to its intended use and practicality.

The major important factor in this process is the glue used. We use an industrial grade glue, which is specific to our application and is applied via compressed air at 60psi. Unlike aerosols which are a much weaker and thinner grade of glue due to the limited pressure contained in an aerosol. The type of glue we use and the process in which it is applied means that we can cover vast areas within its permitted “going off time”. It also means that the glue is far stronger and allows us to mould materials much more easily. The greatest benefit of using our method is that in years to come, the lining material will still be stuck in the same position and not draping off the walls.

The lining carpet that we use is a high quality carpet unlike many easy to apply carpets which are exceptionally easy to mould and shape BUT, have a limited life span and their durability is a problem. Before you decide to have your vehicle lined, be sure to have a pull of the lining material to see how durable it is and how many fibers pull out.

We carry various other lining materials in stock and also supply many other converters. If you require something different we will most likely have it in stock or can source it.

Carpet lining to all walls and rear doors £490 + VAT

Camper van line outs

Flooring

When it comes to floor lining we will only use ‘one piece’ floors made from 12mm 10” x 5” far eastern ply wood, which is routered out on site to accommodate the style of van and the cut outs required. The reason for using this is that the 12mm thickness gives you a decent base to fix to. It doesn’t twist and buckle like thinner floors do, and the reason for cutting floors from such large sheets is to avoid having a join mark down the centre of the floor, which often can be seen when the floor is trimmed and is susceptible to movement. We fix the floor in strategic positions, ensuring that we don’t have lots of screw holes popping out under the chassis and most importantly into fuel tanks. Our screws are put into blind chassis members, so they can’t be seen and aren’t exposed to the elements.

For floor covering we predominantly use an Altro flooring material. This offers a very durable surface that can take a lot of abuse. It’s important to get it right because it can take a lot of rectifying if it is damaged, especially if it’s fitted underneath furniture or seat fixing points. We bond the altro flooring down and cut out to shape, once it is in place ensuring a top quality finish with no gaps around the edges. The pro’s of having an altro floor is that it is easy to wipe out, it’s waterproof, it’s non slip and it is very robust and lasts for years. We do often get customers wanting a more homely feel and who prefer carpet. One solution to this is to have an edge bound carpet overlay mat, which can easily be removed to clean and most importantly can easily be thrown away and replaced when it’s done it’s time or has been damaged. Altro floors are more expensive than that of other products due to the cost of the raw material and also the length of time involved in fitting.

One piece ply floor with hardwearing altro finish £280 + VAT

Camper Van Flooring



Headlinings

Like with our floors, we only use ‘one piece’ headlinings. This gives a much nicer look and avoids having jointing strips in the centre of the roof which are often prone to dropping down. All our fixing points are blind and we don’t use the unsightly VW plastic plugs. We have side trim panels which allow access to run cables from front to back. The roofs are made from far eastern 6mm ply, which is reinforced to avoid twisting and buckling. The roofs we install are capable of carrying large flip down roof monitors. We normally re-mount the VW flush fitting courtesy lights back in central positions and fit flush spotlights in positions that are suitable for the conversion required. We also have LED surround light options available.

The headlining in the rear is usually trimmed in alcantra or a material to match the rest of the vehicle at the customer’s request. We prefer to do it in a contrasting material to the side walls, as it tends to give a much nicer look and a better overall finish.

One piece headlining in choice of fabric or alcantara £260 + VAT

Camper Van Headlinings

Lighting

We have invested a lot of time into researching the best and most efficient products. LED’s use a fraction of the power of other standard bulbs or lights, and they can also deliver amazing power and give the whitest of lights. We have a whole host of LED lights available, depending on your requirements and application.

We offer a range of standard fit lighting, as well as custom options. Usually our lights are switched from appropriate locations and mostly on 2 way switches.

Prices

  • Supply and fit set of 6 LED spotlights on a 2 way switch £180 + VAT (SWB Vans)
  • Supply and fit set of 8 LED spotlights on a 2 way switch £190 + VAT (LWB Vans)
  • Replace all internal courtesy lights with LED bulbs £20 + VAT
  • Supply and fit set of LED surround lights on a 2 way switch £210 + VAT
  • Supply and fit set of 2 LED spotlights in tailgate on a 1 way switch £95 + VAT
  • Supply and fit LED Flexineck reading light £75 + VAT
Camper van lighting

OEM Sunroofs & Rear Air Con

Within the Volkswagen T5 range there are a handful of vans that have extras such as cab sunroofs and rear air-conditioning. This can cause problems for many converters and the overall look can be disappointing when trimmed. At Exploria we have developed ways and methods to overcome these issues, ensuring that the overall look and finish is right.

Having a factory VW sunroof to the cab area means that the cab headlining goes half way into the rear of the van. Trimming half way into the back of the van aesthetically just doesn’t look right. We have a way in which we can trim all the way to the back of the cab seats. We can even trim the cab headlining and A post pillars if required.

The additional cost for lining a T5 with a sunroof is £160 + VAT

Due to the design, rear air conditioning vents in the roof are difficult to trim. The standard headlining has ducting fitted to the topside making it difficult to replace. Most converters just use the original VW headlining trim, which can look poor especially when the rest of the vehicle is nicely lined. At Exploria we replace the complete headlining with a one piece headliner, leaving a nice, neat finish. We fix the original top ducting and original vents which are set on an Alcantara finish.

The additional cost for lining a T5 with rear air conditioning in panel vans / Kombi’s is £160 + VAT

sunroofs for camper vans

Bulkheads

We offer a range of bulkheads to suit your needs. Some bulkheads are ‘off the shelf’ bulkheads and others are custom made. Bulkheads can be trimmed and lined to suit the rest of the vehicle so that it is in keeping with the internals, or lined specifically for the required use. Our customers have various reasons for requiring a bulkhead, some of which are listed below:

  • Keep a clean travelling area separate to the work / tool area
  • Keeping heavy items where they should be in the event of an accident
  • For mounting equipment to
  • Offering a waterproof area in the rear of the vehicle to house wet or dirty equipment
  • Custom shaped to mount specific equipment
  • Keeping pets separate in the rear
  • Removable bulkheads to offer a dual purpose vehicle

Pricing

VW T5 Cab Bulkhead as per factory fitted bulkhead supplied & fitted £160 + VAT

VW T5 Kombi Dexion Bulkhead supplied & fitted £375 + VAT
(extra charges for modification may be required)

Exploria removable timber and aluminium bulkhead £450 + VAT

For custom bulkheads please call for for pricing

Camper Van Bulkheads

Waterproofing

Before lining and trimming your vehicle it is worth considering how the vehicle will be used. If a vehicle is subject to a reasonable amount of water in the back, then it is often worth considering waterproofing. Some of our customers who opt for this tend to be water sports enthusiasts.

Waterproofing the perimeter of the van to ensures that water isn’t allowed to get under the timber floor. This is especially important if salt water is present. It helps to reduce the chances of rust on the floor plan and also reduces the chances of bad smells arising when areas become damp.

To waterproof the perimeter of the vehicle we use fibreglass, which seals the floor to the wall and wheel arch areas. A raised step at the front of the floor stops water getting from the rear of the van onto the cab floor area.

Perimeter floor waterproofing costs £170 + VAT

Full waterproof linings are available if required. We use various materials from GRP to Sprayed rubber linings. Please contact us for further details.

Camper Van Waterproofing

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