The all-new Caravelle Z-bed thread!

[silverbullet]

A while ago I aquired a Multivan rear bench/rock'n'roll bed less it's covers and foams, with a view to modifying it to Caravelle full-width spec for our twin-slider syncro. I got as far as widening the hinges, using our SA Microbus as a guide for correct the dimensions (as they have r'n'r rear benches as standard) the it sort of went on hold, what with one thing and another (wbx rebuild etc.)


That was as far as I got until a mate asked me if I could get him a - wait for it - full-width r'n'r bed for his twin-slider 'velle! A few days later I aquired another genuine SA Microbus rear bench, complete with hinges!
Now since my mate wants to have all-matching original trim in his bus, I reckoned I could modify a standard 'velle fixed bench frame to go on my widened Multivan hinges and his seat covers could go on it (with a little bit of tweaking from the trim shop) and he'd also get enough fabric to cover the engine cover cushion too. Nice!

So now my garage has gone from engine building to looking like a trim shop:


The first thing was to get all the covers off and see how the frames are constructed, then get a plan of action...Now there's more to this than meets the eye, since the 'velle and multivan sets do not have the headrests at the same spacing, so I'd have to take the ends off the m-van backrest (for the catches) and weld them to the 'velle centre part, so his 'velle covers would fit OK with just the ends re-stitched.


Just to give an idea of the differences in the frame widths, these are the seat base frames with one end all flush. M-van on the bottom, SA in the middle and fixed on top:


I figured I'd have to warm up on the seat base before tackling the backrests with their catch mechanisms, so first things first. Cut the legs off the frame, take the longest leg and use them for struts before cutting the ends off the narrowed perimiter frame and re-welding, then check they still fit the hinges!



Next up, the backrests!

[82JEW75]

Watching with interest. Have the fixed rear bench in mine and am building a bed that will fit over it with the backrest folded forwards, but interesting to see if there's a different way to do it...

[Mickyfin]

Interested in this also as I want to use my existing seating to make a bed out of as the material is like new.

[silverbullet]

Doing the backrest is far worse than the seat cushion frame! The SA Caravelle frame that I am using as a pattern increases in width toward the bottom, so the sides of the M-van frame (that carry the catches) had to be cut'n'shut as it was originally parallel sided. Unpicking the catch arrangement was quite fiddly too.
I'd say that unless you're desperate to have a "genuine" Caravelle rock and roller and are happy with trim removal, seat frame modification and fabrication...find a real one as on hours alone it's cost a mint. The trimmers have still got to re-stitch the covers and sort the foams out, but that's down to the customer.
More pics to come and if anyone would like the essential dimensions to have a go themselves, I'll post them up before it goes for trimming.

[silverbullet]

The last couple of Saturdays have seen this little (?) project finaly come to fruition. It's definitely been a case of "do a couple of hours, go and think/have a cuppa/sit down and eat with the kids, do some more later"
Unpicking the backrest support wires:

Backrest release handle unpicked from m-van seat:

M-van ends welded to Caravelle centre section:

Welding details:
Note the cut/weld made top right, allowing the frame to flare toward the bottom:





The finished article, ready to go to the trimmers. Phew!


I should add that without a genuine Caravelle/SA rock'n'roll bench that I could strip down and use for reference, this job would have been just about impossible or at the very least incredibly time-consuming...like it hasn't aken enough hours anyway!

[silverbullet]

A few critical dimensions as promised, if you fancy having a go with that old Multivan bench seat in the back of the garage

Seat base frame: 1590 wide, 1540 at rear (doglegged, parallel sides), 430 deep, first hinge fixing hole 180 from back edge.

Backrest: 1595 wide at bottom, 1515 over catch backets/1550 over catches inc. plastic covers; 460 high;
Cut in end portions (to achieve 1595 dimension) made at approx. 290 from bottom outer corners, just below second bend below catches.

All of this to retain the Caravelle headrest spacing of 530mm, allowing the matching covers to be retained, once re-stitched on the ends.

Don't forget that the backrest will need a new foam making, in addition to the seat cushion being narrowed down and also re-stitched.

Forgot to add that the hinge assembly (tube) needed to be widened by ~95mm. Easiest approach is as per the first picin this thread: cut in middle, bolt into van then check the gap. No need to allow for the trim as the hinge assembly will spring enough to clear the cards.

Clear as mud

[Epiphone]

Hi, the bar that goes across the full width of the bench, near by where your feet are, when sitting?

Is this really necessary? Ive put 6x9 speakers there and the bar is slightly in the way.

Would it really reduce the strength of the bench if it was to be cut off?

or is the only substitute to not having that bar accross is to have a standard bench (non-bed) and then fit rock-n-roll hinges?

[CovKid]

Looking at it, I would suggest its essential otherwise there is nothing to really stop the frame moving out of shape. However, providing you can come up with supports to the sides that don't get in the way of the z mechanism, you should be able to get around the problem. Difficult to judge without seeing how it moves and what stays still In any event, its not just the bed movement you have to consider but the overall strength of the unit as a seat should the worst happen.

[silverbullet]

I do know folks who have cut the tube on multivan hinges to make full-width seat/beds and not bothered to re-join it, relying on the seat base to keep it all square and lined up.
It's not a good idea imho. Especially when using boards intead of proper metal frames (JK springs to mind)

[CovKid]

Well put Silverbullet. It just isn't worth compromising the safety of passengers. I mentioned all this in my DIY rear seat mod and why I was so keen to strip out what was there and fit something more substantial. I like the idea of the z-bed fit. It was something I toyed with for months before I fitted my present seat. I'd say if anything, that additional bracing pieces are a good move even if it means bolting to the sides here and there. Anything has to be better than MDF and flimsy L brackets