All prices are in Australian Dollar (AUD)
The van will have 3 gas components inside, the hot water unit, the cooktop and the gas box itself. I’m allowed to mount the gas components myself provided they comply with Australian gas standards, but I’m not allowed to run gas lines and fit them off.
I bought my instantaneous gas hot water heater from Camec in Brisbane Australia. The unit automatically turns itself on and off by detecting flow of water when you turn on a hot water tap. Hot water will supply my shower and my sink.
My gas box is custom made for the Sprinter because it contours to the curve on the side of the van. It houses up to a 4kg gas bottle inside, and is made from fiberglass. It includes a lock to install and an un-sealed door to outside, so there isn’t a need to put a vent on the door.
1kg of LPG gas = 49Mj
4kg of LPG gas = 196Mj
My hot water unit in theory uses 0.63Mj of gas per minute. If I have a 2 minute shower per day that is 1.26Mj per day. Roughly allowing for the gas cooker and rounding up lets say I use 4Mj per day.
Instantaneous Gas Hot Water Unit – AU$890 – CAMEC
1. First I measured up the best fit for the gas box relative to my surfboard.
2. Then I eyed up how the gas box is actually going to fit on the side of the van and measure the gas box dimensions itself.
3. I measured up roughly on the outside of the van to get an idea of how it would fit visually.
4. Then I did my best to transfer these lines to inside of the van, then marked out and cut the dimensions inside.
5. I drilled a small reference hole to measure on the outside.
6. I measured accurately from the reference hole, and had to use the sliding door gap as a straight verticle edge reference to get the measurements square.
7. Once measured up I cut it out with a grinder and hammered the parts the grinder couldnt reach flat with a hammer.
8. I measured up and cut out some of the subfloor with a sabersaw so the gas box could recess in.
9. I filed the burred edges and tested the gas box would fit before painting it with rust protector coat.
10. Next I measured up the hot water system internal cut out and cut with a grinder.
11. I am using 35mm x 70mm cut offs of pine as a base for the hot water unit.
12. I marked out the top and side of the box then drilled 2 reference holes through the external metal.
13. I used these reference holes to measure up the cutout.
14. Then I screwed down the timbers for the base with 65mm batten screws.
15. I checked that the box fit, then pre drilled and screwed in the top 3 screws first. Then I predrilled the rest of the holes.
16. I cut a small timber strip for the top 3 screws to offer extra support.
17. I taped around the box flush with the edges, then applied Sikaflex Pro around the whole internal edge. Once you’ve pushed the box in, and neatened up all the edges with a wet finger, take off the tape for a neat finish.
Note: If you get any Sika on the black plastic strip of the van, use a dry rag to remove, not a wet one.
18. Once happy, I covered with taped up glad wrap and built some extra timber supports to hold firmly in place.
19. Back to the gas box, I marked out 3 holes for the door hinge and pre drilled them. I then eyed the hinge up on the box and marked and pre drilled on the box.
I tapped these holes on the box with screws, before applying Sika Pro to the hinge and securing the hinge to the box.
20. I then repeated this process for securing the door on the hinge.
21. I grinded the protruding screws flush with the fiberglass, and sealed them with Sika Flex.
22. I used the tape trick, then adhered and sealed the gas box to the van (purely with Sika Pro).
23. I measured and cut the hole for the lock with an 18mm holesaw. Then I used a piece of aluminium angle for the catch and secured it down with Sika Pro.
24. I cut 2 bits of timber to wedge underneath the gas box to support the weight of the gas bottle, then I secured them with Sika.
I also applied Sika to the backside around the gas bux on the inside of the van for extra support.
Congratulations, now you’ve installed the gas box and hot water unit!
Some of these prices are discounted either from bulk buy or trade price. All prices are in AUD$
|4kg Gas Box||1||280||280|
|Sika Nozzles (3 pack)||2||2.18||4.36|