Karmann Coachbuilts

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Karmann LT

Distance Wide



Stephen Calvert


Page 02



With the Distance Wide stripped of it's aluminium skin it's time to start rebuilding it.





51. The first of the new framing is laid

down using kilned dried wood. The

old framing is copied precisely.

52. Everything relies on this first length

of wood being right.

53. After days days work copying the

old framing the wall is almost




54. The ensure openings are correct

the aluminium side panel is used as a template.

55. Another opening...

56. The new framing is removed from the van for more work.


57. The complete wall ready for

routering the 28mm channel.

58. 28mm channel on the rear nearside corner.

59. More routering of the channel



63. With the nearside framing now

complete it is temporarily mounted

back on the Distance Wide.

64. Before the wall can be permanently placed on the van the toilet floor is repaired.

65. This will of course be protected



66. The old side wall is removed from the Distance Wide

67. Everything is checked over in

readiness for the new wall.

68. Traces of old sealant is removed

and the area cleaned.



69. Everything is checked over to ensure it's a good fit.

70. Inside of the new framing is marked

with a pencil around the furniture and

wall so that it is know where the

wallboards and screws will go.

71. The rear lower offside and the new toilet access opening.



72. The new wall boards are laid out on

the new framing ready for fixing on.

73. Weights are used to make sure

a good fix..


74. The new wall boarding is ready

and windows openings are cut

using a router.



75. At last the new wall is fixed to

the van

76. Old School! A current dated coin

is left on the framing.

77. Bulkhead fixing bolt.



60. The new wall viewed from the

inside. This is the corner of the lounge


61. Toilet wall bottom. The cassette

access door is yet to be cut out.

62. Toilet window.



78. The gas locker.

79. New coloured welting is stapled onto the bottom of the 28mm channel.

80. With the wall nearing completion, protective paint is applied to bottom edges.



81. New aluminium railing fixed.

82. Wall is now complete. Time to move onto the next job.

83. Framing on the rear wall is copied.




84. The old back wall is removed and the new wall offered up and checked..

85. Rear wall ready for the new wall boarding.

86. The new wallboarding is now glued

to the new framing and the rear

wall fixed to the van.



87. Onto the offside. This drawing was discover on the door frame.

88. Only a small amount of repairs were needed on this side. Offside rear lower corner has some new wood grafted in.

89. New wood is used to replaced the rotted wood on the side step.



90. Clamped and gued.

91. Finally, protective paint is used.

This side is done.

92. Onto the overhead cab. The strengthening padded bar is removed.



93. The fibreglass edge is cleaned.

94. Inside and out. Repairs are made if needed.

95. New strengthening bar is installed.



96. Silicone sealant should be used where the bar meets the fibreglass base.

97. New welting is stapled into the 28mm channel.

98. New front wall is made and offered up.



99. A new overhead can roof is made using the old roof as a pattern.

100. The new roof placed onto the

Distance Wide.

101. The roof is supported in the middle

until the new front wall in fixed.


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