Hole advice please..?

[Ernesto]

The time has come for refillable gas ...inspired by how easy Minxy Girl made it look, my next lockdown project will be fitting two 11Kg Gaslow cylinders. There seems to be an ideal filler location in the rear bumper - enough space behind for a 90 degree elbow, enough room for the pump nozzle and the bumper is very strong at that point too

The filler pipe will run up to the gas locker and through the vent in the floor - which means drilling a hole in the fairly robust metal mesh thats currently fitted - has anyone tried this or something similar, and could share any tips on making a neat job of it please? My first thoughts are a hole saw, but that might bounce around and make a right mess....metal sheare/tin snips would also not be neat and potentially leave sharp edges...?

 

[SpeedyDux]

Um ... what could happen if you are in a rear-end collision?

 

[Richard n Ann]

Think there will be a flange round it to cover the edge of the cut

 

[Landy Andy]

Can see pics as site not working, but if it’s like my drop vent then it’s set down the bottom of recess. If this is the case I would make an infill for that, cut the round hole in it and then use that to support the drill as it goes through the mess. Don’t forget you will need to fit a grommet to the mesh to protect the gas pipe going through it.

 

[tonyidle]

The time has come for refillable gas ...inspired by how easy Minxy Girl made it look, my next lockdown project will be fitting two 11Kg Gaslow cylinders. There seems to be an ideal filler location in the rear bumper - enough space behind for a 90 degree elbow, enough room for the pump nozzle and the bumper is very strong at that point too

<Broken link removed>

The filler pipe will run up to the gas locker and through the vent in the floor - which means drilling a hole in the fairly robust metal mesh thats currently fitted - has anyone tried this or something similar, and could share any tips on making a neat job of it please? My first thoughts are a hole saw, but that might bounce around and make a right mess....metal sheare/tin snips would also not be neat and potentially leave sharp edges...?

<Broken link removed>

Use side cutters. You're right about the hole saw - don't try it .

Although personally I'd put it in the locker.

^{_{Subscribers  do not see these advertisements}}

 

[Ernesto]

Um ... what could happen if you are in a rear-end collision?

I guess its the same as if someone pulled out from a side road and T-boned us, and we’d installed it in the side? Statistically speaking I guess the chances of a rear end shunt are slightly higher... but then we wouldn’t be paying for the repairs I suppose

 

[Silver-Fox]

You could “sandwich” the mesh with ply.
Just put a piece either side and screw the ply together.

No problem putting a hole saw through the mesh then

 

[SpeedyDux]

I guess its the same as if someone pulled out from a side road and T-boned us, and we’d installed it in the side? Statistically speaking I guess the chances of a rear end shunt are slightly higher... but then we wouldn’t be paying for the repairs I suppose

In a side collision your insurance company would have less reason to dispute your claim. Going down your suggested route, it might be adviseable to ask first what effect your proposed modification will have on their policy cover and premium.

 

[Ernesto]

Use side cutters. You're right about the hole saw - don't try it .

Although personally I'd put it in the locker.

Thought about locker door - for me, not so keen as suspect garage attendants will start to get interested if rear doors are open...but thats just me - may not happen to many people often in real life
Side cutters good call thanks

 

[Ernesto]

You could “sandwich” the mesh with ply.
Just put a piece either side and screw the ply together.

No problem putting a hole saw through the mesh then

Good one thanks - feels like I would have fewer sharp edges to have to deal with if I could use hole saw - and double ply very cunning

^{_{Subscribers  do not see these advertisements}}

 

[Silver-Fox]

Good one thanks - feels like I would have fewer sharp edges to have to deal with if I could use hole saw - and double ply very cunning

It will give you a clean round cut.

I couldn’t live with a hole that wasn’t round even it it’s covered up.

Im a bit ocd

 

[Ernesto]

In a side collision your insurance company would have less reason to dispute your claim. Going down your suggested route, it might be adviseable to ask first what effect your proposed modification will have on their policy cover and premium.

Not sure the impact direction affects the risk of disputes from insurer? Rear-ending someone is very very tricky to pin the blame on anyone else. I managed it once in a car - but was able to explain it due to the Ford Escort piling into the back of us first, and pushing us into the car in front ...

Side swipes much easier to contest I would have thought and more likely to lead to 50/50 settlements

I agree though that there is question whether the insurer would for example pay out on a total loss, for the refillable gas system as well, if you hadn‘t declared it, but the extra cost over the delivery spec of the van is only a few hundred quid so not to worried about that

 

[Lenny HB]

Um ... what could happen if you are in a rear-end collision?

Not much only a bit of gas in the pipe, if it did rupture, nothing to worry about.

 

[SpeedyDux]

Not sure the impact direction affects the risk of disputes from insurer? Rear-ending someone is very very tricky to pin the blame on anyone else. I managed it once in a car - but was able to explain it due to the Ford Escort piling into the back of us first, and pushing us into the car in front ...

Side swipes much easier to contest I would have thought and more likely to lead to 50/50 settlements

I agree though that there is question whether the insurer would for example pay out on a total loss, for the refillable gas system as well, if you hadn‘t declared it, but the extra cost over the delivery spec of the van is only a few hundred quid so not to worried about that

Not wishing to go into this much further, but my point is that side mounted fillers are commonplace, so less likely to be contestable as a modification than a filler mounted in the vulnerable back bumper. All policies require modifications to be notified and failure to do so may result in the insurer avoiding the policy in the event of a claim.

 

[spongebob]

Try car edge trim seal Ebay have different sizes

^{_{Subscribers  do not see these advertisements}}

 

[donkey]

Hi
Your PVC looks similar to mine. I located the filler on a bracket from the side step frame. It is well protected and removable when it comes time to change vehicles. Also only needed a short filler hose.
Geoff

 

[Ernesto]

Not wishing to go into this much further, but my point is that side mounted fillers are commonplace, so less likely to be contestable as a modification than a filler mounted in the vulnerable back bumper. All policies require modifications to be notified and failure to do so may result in the insurer avoiding the policy in the event of a claim.

Appreciate the input I agree - irrespective of where the filler is, its good practice to advise insurers of all mods.

 

[Ernesto]

Hi
Your PVC looks similar to mine. I located the filler on a bracket from the side step frame. It is well protected and removable when it comes time to change vehicles. Also only needed a short filler hose.
Geoff

Unfortunately our step is on the offside, and the gas locker on the rear near side - thanks for the idea though - may definitely help others

 

[Terry]

Hole saw all day long you will never get a perfectly round hole with side cutters.There is only a couple of mm cover on the flange side of things. I don't know why you think a hole cutter will bounce all over the place ? They come with a drill bit in the middle about half inch longer than the saw bit so that drills a hole which holds the saw blade bit in place.
You can also buy a fixing bracket (approx£20ish) that you could tec screw to the van floor that will just fit under the rear bumper or the side of the van,your choice would personally use the bracket that way you are not drilling the van and it's easy.As to the gas pipe simply drill through the mesh and either fit a gromet or wrap a good bit of gaffer tape around the pipe where it may rub. Only an hour or with a coffee break two at most

 

[mitzimad]

my kit came with a plastic sleve for the fill hose to pass through the floor if you have one of those i would leave the mesh intact and drill a seperate hole through the floor trying to pass through expanded mesh is never going to be neat
https://www.autogasshop.co.uk/floor-seal-19-28mm-1770-p.asp not the same as mine which is flanged and longer

^{_{Subscribers  do not see these advertisements}}

 

[lynnian]

Try one of these cutters/ punch from Amazon will cut through wire mesh without grab from the teeth. Various sizes

 

[Ernesto]

Hole saw all day long you will never get a perfectly round hole with side cutters.There is only a couple of mm cover on the flange side of things. I don't know why you think a hole cutter will bounce all over the place ? They come with a drill bit in the middle about half inch longer than the saw bit so that drills a hole which holds the saw blade bit in place.
You can also buy a fixing bracket (approx£20ish) that you could tec screw to the van floor that will just fit under the rear bumper or the side of the van,your choice would personally use the bracket that way you are not drilling the van and it's easy.As to the gas pipe simply drill through the mesh and either fit a gromet or wrap a good bit of gaffer tape around the pipe where it may rub. Only an hour or with a coffee break two at most

I was worried with the hole cutter because the drill bit might snag on the holes in the mesh - using some ply would definitely prevent this. I’m planning on using the small square filler rather than the bigger circular one, as I reckon it looks a bit neater and with the black cover in place, it will be invisible abgainst the back bumper - this pic from another thread shows it installed on another van....

 

[Ernesto]

my kit came with a plastic sleve for the fill hose to pass through the floor if you have one of those i would leave the mesh intact and drill a seperate hole through the floor trying to pass through expanded mesh is never going to be neat
https://www.autogasshop.co.uk/floor-seal-19-28mm-1770-p.asp not the same as mine which is flanged and longer

Thanks - a proprietary seal would be neat.

 

[Minxy]

Not sure if you're read the below but this is how I put it in the skirt of my Carthago, whilst your location is different the process is the same:

Gas It - Query

Hi All, Looking at putting in a 11kg and 6kg Gasit System, I don't really want to go drilling into skirt of MH, is there any reason external filler couldn't be attached to the Gas Locker Door? Thanks a mill. Gordon

www.motorhomefun.co.uk

 

[jezport]

Autogas 2000 sell a sill mount for fitting under the edge of the sill. No cutting and neat.

^{_{Subscribers  do not see these advertisements}}

 

[Terry]

I was worried with the hole cutter because the drill bit might snag on the holes in the mesh - using some ply would definitely prevent this. I’m planning on using the small square filler rather than the bigger circular one, as I reckon it looks a bit neater and with the black cover in place, it will be invisible abgainst the back bumper - this pic from another thread shows it installed on another van....

View attachment 464156

Once the filler is in place it goes to a half inch pipe so going through the mesh is not a problem.You could even knock a hole through the mesh with a chisel which would round the mesh off , not giving you a sharp edge for the pipe to rub on . Although the filler face is Square the ones I have fitted are round at the back hence hole saw. If fitting in the place you indicate then you have to get into the rear quarter panel to fix the filler to the bodywork ( tight )
Use a quarter inch chisel with a round Handel that you knock all the way through the mesh

 

[Terry]

Autogas 2000 sell a sill mount for fitting under the edge of the sill. No cutting and neat.

Hi Jez,That's the bracket I mentioned real easy

 

[Raul]

Definitely hole saw. I did it for the water, gas and electric. Not a problem. Get a piece of ply, drill through that and use it as a guide as well as the pilot. No movement. Best cutter For steel I found to be starrett. Bosch bi metal and erbauer works well to. There is a sleeve with drop out that is used for the high pressure line on gas it site. I got my kit built up in bits as I wanted different items to what they offered as a kit. The sleeve is designed that if the line ruptures, it escapes out rather than just a grommet. Much safer. As for bumper location, they do a bracket as well, if you don’t want holes in there.

 

[Ernesto]

Just in case it helps anyone else - reason I’m going through here is a) I’m drilling into a small strong part of the plastic bumper so should be relatively easy to replace if anyone ever wants to and b) easy access - no need to access behind any panels
See photo below - all I’ve done is held the iPad under the back corner of the van - to orientate, the bottom of the photo is the bottom corner of the bumper nearest the ground, the nut and bolt is holding the red reflector, then the space for the 90 deg elbow (and room to get my hand up there), next theres the rubber bump stop and then the point of light is where the door hinge attaches .....the blue is just the head torch

 

[Ernesto]

Reposting photo as doesnt seem to have loaded

^{_{Subscribers  do not see these advertisements}}