On July 24th
the first "work" was done at Alu-Star.
Alu-Star in Schallstadt (Freiburg im Breisgau, Germany).
We stayed on-site over night in our Defender and enjoyed
the "luxury" of our roof tent.
On Saturday Alex came in to work with Ruedi. It was
The measurements of the bicycle "garage" were
checked and a replica built.
Alex and Ruedi discussing how to attach the bicycle
in the garage.
Ruedi's plans are correct. Details were discussed.
Building of the camper cabin
The roof with 2 openings in the roof, the floor, the
front and left hand side wall are being built.
View into the cabin from the front; 2 views of the
Delivery of the camper cabin
On January 21st, 2005 the empty camper cabin is delivered
on a 40 ton truck.
Carefully the 900 kg weighting cabin is lifted from
the truck with 2 straps.
The cabin will now be finished standing on a assembly-platform
Everything is checked carefully for damages in transit.
All measurements are controlled.
All is fine and Ruedi seems to be delighted.
Details of the split door.
During February the tubes for the floor heating are
being installed by Alex
The boiler will also serve as accumulator for the floor
The tubes are then covered with metal sheet. Even with
this tedious work Alex keeps his sense of humor by proposing
degreasing spray as deodorant.
Beginning of March the floor is finished, the linoleum
fitted and the first peace or furniture built.
It is time for sampling now.
With cake and coffee discussing colors and materials
is much easier.
We cannot decide if we should go for colors or wood.
To help Alex shows the difference between "rolled"
or "coated" paint.
We go for the rolled one.
At the end, as the floor is made of a dark grey linoleum,
we decide to go for off-white walls with colored spots
and the furniture doors will be light grey timber laminate.
For the kitchen bench-tops and the dining table a matching
Corian top is chosen.
The choice of the upholstery is not easy. At the end
we settle for light-brown Alcantara.
Color will be added to the interior with bed-linen,
towels, cushions, etc.
The furniture is developed
The last few fixing points are applied and the cabinet
for the kitchen sink is set in it's place.
Ruedi seems to be skeptical and checks a few dimensions.
The fridge looks fine.
Ruedi and Alex check the height of the window by sitting
on makeshift seats .... especially Alex ....
The windows have arrived. Alex explains the functionality
On Easter the next visit is paid to Alu-Star. Thomas
has come back from a job up north and is now working
on our window frames.
Alex has generated an overhead compartment. We need
to decide if the doors should open upwards or downwards.
Due to the constraints of the hinges we decide to open
towards the ceiling.
Also the top-section of the kitchen element needs to
Some things can not be decided just on paper, it requires
discussions in front of the object.
As the element will contain Ruedi's guitars Ruedi also
opts for the door to open towards the ceiling.
The windows will be equipped with aluminum"blinds"
that can be locked from the inside.
These blinds are meant as protection against burglary
and environment but also to make the camper a bit less
Ruedi wonders who many wholes need to be drilled into
the blind to allow some sight of what is happening outside
without on the other hand revealing to much of the camper
hidden in the container.
We decide on one whole as more often than not one doesn't
want to be detected than one needs to look outside through
the closed "blinds".
At lunch time we all gather outside and enjoy some
Pizza together with some beautiful warm sun shine.
Solar panels, emergency escape
It is already April. Ruedi's father, Max, comes along
Thomas is ready to start the installation of the solar
All is discussed and the planned setup re-inspected
from all sides.
Hansjörg and Alex work on the emergency escape
into the driver's cabin. It seems to jam a bit.
All is removed again, cut open, welded again and then
it fits perfectly.
How should we solve the mozzie-screen door? There also
must be a grille to prevent the opening of the door
so the top section can be left open open night.
In spite of some good ideas and once again studying
the catalog the problem is not solved.
Well, we also need something to discuss next time, right?
Solar panels finished, windows and blinds,
roof window, sampling again
In May Ruedi is at Alu-Star for 2 weeks to help.
The water filter system is built and together with
the UV-filter installed in the kitchen cabinet.
Over and over again they realize that the furniture
lacks a metal piece here, and additional whole needs
to be drilled there.
When testing if the Rako-Boxes fit into their destination
spots they find that the drawer for the pots and pans
is not wide enough by 4 mm meaning that the Rako-Box
does not fit.
Alex wants to take the furniture apart and fix it properly,
but there is no time. The furniture should have been
handed over to the painter a while ago!
So it is decided to build an Aluminum-drawer to take
the place of the Rako-Box. Guess the pots and pans will
The Solar system is ready.
For easier tracking of faults always 2 panels are connected
into the cabin over one wire.
When Ruedi wants to test if the system works he has
to realize that there is no sun shining inside of the
Thomas is working on the second roof window. The first
one stands in the office, ready to be mounted.
The resistant Macrolon is extremely flexible and is
Alex is not happy with the quality of work done on
he hinges. He orders the cargo doors to be removed again.
Then the hinges get removed too. As they have been glued
in with Sikaflex this takes some time.
New hinges are fitted correctly. Now the work is up
The last window to be mounted is the one at the dining
Hmmm ..... the mounting place is 3 mm to small. Alex
needs to cut it out a bit more.
Ruedi removes the metal dust so it does not get into
the mounting material.
The window now fits perfectly.
On the other side of the cabin the windows are already
They can be fixed on any height.
Once the window has been closed at the end the blind
is closed. Once the blinds are painted once will not
see much of the camper hidden in it.
Some of the materials and colors that we chose a few
weeks back are not available anymore because their companies
have ben taken over by another one.
All except the Corian and the linoleum which is already
mounted needs to be sampled again.
After another long discussion we decide to go for painted
furniture. We choose a RAL-color as they are available
globally and potential dentures and scratches can be
repaired by us.
The new colors are:
Furniture frame: Alu silk
Doors: RAL 1015, bright ivory
Seat covers: Alcantara-similar material from Sonnhaus,
washable, Tiffany silver