New van conversion

del88

Hi
I'm hoping to start a van conversion this month...very exciting.
I'm looking at a lwb, high roof, ford transit (front wheel drive,low floor)this week .
I'm a carpenter and have worked for a furniture designer in the past so would be fairly confident with the internal furniture.I've limited experience with plumbing,electrics ect but am looking forward to give them a go.
As far a lay out goes i was thinking something similar to the autocruise alto
http://www.autocruise.co.uk/van-conversions/360-views
Also here's a link to a 360 degree view..

I've been reading a lot of conversion blogs and this forum of course and am hoping to do everything myself....
Also i'm on a tight budget so any advice on money saving tips or were to pick up bargins would be much appreciated.
So here's the shoping list.

1. Insulation....probably go for rockwool on the sides and kingspan (25mm) top and bottom...then battened out and ply.seen a good idea where a recess was left in the floor to take wiring and plumbing.
2. Bathroom....proably the most expensive part....shower tray,toilet,flip up sink,3mm plastic sheets for walls,shower head....
3. Windows, roof lights.....seitz seem to be the most popular but quite expensive..founds some on ebay that claim to be like seitz a lot cheaper...will need 2 for the sides (900*450) and one for the back door(500*450).I'd love a nice big rooflight for the front and a small rooflight/vent for the back
4. Sink and hob...seen this one for £150 at www.camper-parts.net .seems to be a decent enough price considering the same one was £200 on another site.
5. oven...again seen this one for £240
6. Seats....so i'm going to need a new single passenger front seat,a pair of swevil brackets and move the the double front seat into the back along with new seat belts....have a friend who's a metal fabricater so hoping to get help from him making any adjustments.
7. Bed....i really like the bed seup in the autocruise alto..it has a fold up frame that allows acces to the back door and under bed storage....http://www.autocruise.co.uk/uploads/Reviews/Autocruise%20Alto.pdf as for the matress ,might look at adjusting a standard matress or making one to shape from meomry foam.I also seen an idea for a bed to the front that hangs from the roof at the 4 corners to give a double bed but will need to look more in to this..
8. Fridge....again a like the position of the fridge in the alto...it's up high so it's over the bottom of the bed giving more room for the the bed itself. Seen a 3-way fridge for £355 at www.rainbowconvertions.co.uk
9. Water heater and air heater....I've seen some that run of gas that do both so will look more in to that.
10. Electrics...this is something i don't now a lot about...i think i'll need a zig type unit and lots of wires:)internal lighting run of 12v and mains..3 mains plug sockets
11. Plumbing...shouldn't be to tricky...fresh water tank,waste water tank....somewhere for gas .
12. upholstery...not sur about this...my mother is handy enough with a sewing machine so might talk nicely to her about that one...i'd probably give putting material on walls ago myself.
13. Furniture....Do this for a living so looking forward to this ..might go for a mix of wallnut and beech or cherry.....
14. The outside....don't want to have to do a respay so probably just a good clean up and some nice graphics..

So that kind of the plan...still a lot of home work and of course try find the right van..

del88

Just found a web site that sells rubber seal windows.
http://www.leisurevehiclewindows.co.uk/vehicle-window-brochures/Rubber-Fit-Window-Accessories-2009.pdf
There a fraction of the cost of seitz windows although not as nice.
Maybe go for a mix of the two.

Buford T Justice

Hi

Will be soon starting a conversion myself. In regards to a van, I did aquire a LWB transit like this one only with a single axle.

Windows. My van already has a window fitted on the sliding door, so I've sourced a few windows from a mini bus for €40 each. Much cheaper than a seitz version.

In terms of wiring, there is plenty of help out there on how to do it. Check out the Self Builders Corner thread, it has plenty of links to sites. Personally, I did buy the Haynes manual for building camper vans. A lot of the book is guff, but there are some good sections in it. I've spent some years as a spark so this part of it doesn't really bother me.

Plese let us know how you are getting on, and what van you get etc.... as tips and tricks as you go along will be a great help. I intend to do likewise.

peasant

del88 wrote: »

Just found a web site that sells rubber seal windows.
http://www.leisurevehiclewindows.co.uk/vehicle-window-brochures/Rubber-Fit-Window-Accessories-2009.pdf
There a fraction of the cost of seitz windows although not as nice.
Maybe go for a mix of the two.

You do realise that with their aluminium frame even in the double glazed version they will be a cold bridge in your insulation and a source for endless condensation and thus ...eventually... rust?

Also, Rockwool (or similar) is not very suitable for insulating vans. It has a tendency to sag, exposing naked section of sheet metal and, much worse, it also absorbs water (condensation), chanelling it into metal folds, breeding rust

Materials that come highly recommended are armaflex or x-treme isolator. Those are closed pore foams that do not absorb water and that can be glued straight to the metal panels.

del88

Fingers McGee wrote: »

Hi

Will be soon starting a conversion myself. In regards to a van, I did aquire a LWB transit like this one only with a single axle.

Windows. My van already has a window fitted on the sliding door, so I've sourced a few windows from a mini bus for €40 each. Much cheaper than a seitz version.

In terms of wiring, there is plenty of help out there on how to do it. Check out the Self Builders Corner thread, it has plenty of links to sites. Personally, I did buy the Haynes manual for building camper vans. A lot of the book is guff, but there are some good sections in it. I've spent some years as a spark so this part of it doesn't really bother me.

Plese let us know how you are getting on, and what van you get etc.... as tips and tricks as you go along will be a great help. I intend to do likewise.

Hi fingers
Cheers, i'll try get the haynes manual...i'm trying to get as much info as possible at the moment so that should come in handy....
ye thats a good idea for tip and tricks...if i see anything that looks good i'll stick it up..
That van looks the job .....Whats your plan for the lay out?

del88

peasant wrote: »

You do realise that with their aluminium frame even in the double glazed version they will be a cold bridge in your insulation and a source for endless condensation and thus ...eventually... rust?

Also, Rockwool (or similar) is not very suitable for insulating vans. It has a tendency to sag, exposing naked section of sheet metal and, much worse, it also absorbs water (condensation), chanelling it into metal folds, breeding rust

Materials that come highly recommended are armaflex or x-treme isolator. Those are closed pore foams that do not absorb water and that can be glued straight to the metal panels.

Hi peasant.
That's just the sort of feedback i was hoping for...What sort of windows would you recomend?
Would this type be the same?

https://www.youtube.com/watch?v=eDWnJa0wl2o

Won't be using rockwool so ...dampness is probably the biggest thing i want to avoid...once the insulation is closed in there will be not way of changing it....i think i'll use a vapour barrier as well.
Any more advice would be greatly appreciated .

peasant

del88 wrote: »

...What sort of windows would you recomend?

Firts off, I have never converted a van, so I'm by no means an authority on the subject.

I would prefer the seitz type window for better insulation and less condensation.
Having said that, their framing is different and they don't just fit into the cutout like the rubber seal windows do, afaik they need some sort of wooden sub-frame.

If you could place the rubber seal windows in such a way that condensation from the frame doesn't soak/rot anything and if you were prepared to take them out again after a few years to treat the cutout underneath for signs of rust, they may well do the job

Buford T Justice

del88 wrote: »

That van looks the job .....Whats your plan for the lay out?

Thats not actually my van, but mine is a very similar one. Don't have any pics yet

As for the Layout, I haven't planned one yet so I'm open to suggestions. Will be workin on a layout this week. Honestly don't think i'll bother with a toilet, but again, I'm open to correction on it so would appreciate any feedback.

peasant wrote: »

Also, Rockwool (or similar) is not very suitable for insulating vans. It has a tendency to sag, exposing naked section of sheet metal and, much worse, it also absorbs water (condensation), chanelling it into metal folds, breeding rust

Materials that come highly recommended are armaflex or x-treme isolator. Those are closed pore foams that do not absorb water and that can be glued straight to the metal panels.

Any ideas of who does them locally round Sligo Pesant by any chance?

peasant

Fingers McGee wrote: »

Any ideas of who does them locally round Sligo Pesant by any chance?

unfortunately not

what you're looking for is material that's like those thin foam mattresses that are used for hiking and camping.
like this: http://reimonew.ms-visucom.de/en/50022-x_trem_20mm_1450breit_lfm/

del88

Seen this on donedeal...new shaped fiat ducato extra long wheel base ,high roof,33000 miles for E11,900..looks nice and clean.
I've sent an e-mail off for more info....don't want to rush in but this looks a good deal.

del88

Fingers McGee wrote: »

Thats not actually my van, but mine is a very similar one. Don't have any pics yet

As for the Layout, I haven't planned one yet so I'm open to suggestions. Will be workin on a layout this week. Honestly don't think i'll bother with a toilet, but again, I'm open to correction on it so would appreciate any feedback.



Any ideas of who does them locally round Sligo Pesant by any chance?

I'd defo go for a toilet...as for the layout ,find one you like ,thats suits what you plan to do with the van then copy it....
I like the autocruise alto because of the way the bed flips up...i do Kayaking so will have no problem getting them in down the centre of the van...

Buford T Justice

Clearly your idea of a tight budget and my idea of one are two different things. Going with €11.8K as a budge for a van, I would recommend:

This. Serious bit of machinery

03 Wagon for €3.5K and a crew cab, so will have windows etc in back.

Or This:

05 LWB Hi Roof for €6K

Or This even:

This is a 07 LWB HI ROOF and is coming in under 10K. Much better value imo.

Then again, maybe this:

06 LWB HI Roof for €7.3K


Can you tell that I'm a fan of the Iveco? They are serious machines and are massive, if its size you're looking for with that budget. I think you'd need to be bonkers to get a fiat over these wagons.

Do you know anywhere that has plans or layouts laid out online that I can look at?

defike

I recently purchased new shape ducato for conversion.Figured will want it to last 20+yrs so should be in good order to start.Have fitted 2 seitz windows.Insulation is foil backed fiberglass plus a layer of 2L2(silver bubble wrap)This comes with aluminium foil which when sealed acts as a vapour barrier.

del88

Fingers McGee wrote: »

Clearly your idea of a tight budget and my idea of one are two different things. Going with €11.8K as a budge for a van, I would recommend:


Do you know anywhere that has plans or layouts laid out online that I can look at?

ye the van budget has gone up ...talked my father into partly funding my project with the promise of shared usage....
ye the iveco is some van...i'm going looking at vans on saturday inside and out so will try look at some ivecos as well..

Here's a few sites with layouts that are possible in panel vans.

http://www.tributemotorhomes.co.uk/layout.htm
http://www.autocruise.co.uk/van-conversions
http://www.swiftleisure.co.uk/motorhomes/mondial/mondial-range/layouts
http://www.chaussonmotorhomes.co.uk/chausson_twist_02_2010.php
http://www.motorhomechooser.co.uk/featured-timbdestiny-d.php

del88

defike wrote: »

I recently purchased new shape ducato for conversion.Figured will want it to last 20+yrs so should be in good order to start.Have fitted 2 seitz windows.Insulation is foil backed fiberglass plus a layer of 2L2(silver bubble wrap)This comes with aluminium foil which when sealed acts as a vapour barrier.

ye i love the ducato...lovely shape
where did you get the bubble wrap...hey it would be fantastic if you could stick up a list of everything you bought and where you got it...
would be great if you could stick a few photos up also:D

Buford T Justice

del88 wrote: »

ye i love the ducato...lovely shape
where did you get the bubble wrap...hey it would be fantastic if you could stick up a list of everything you bought and where you got it...
would be great if you could stick a few photos up also:D

I dunno, Ducato's are just Meh to me.. I think the Iveco give more of an 'I'm Big, get outta my way or I'll pummel you' sort of feel, which I like. Pity I can't afford one though, I'm stuck with a transit. Still though...

I think something along the lines of this thermawrap would be the bubblewrap type thing.

Will be doing my own conversion soon (hopefully making an actual start next friday) so will start my own thread on how and what I'm doing then.

peasant

Before applying any insulation I would make sure that all the seams, folds, nooks and crannies where water could run into or sit in are waxoyled.

You'll never get at those areas as easily again

defike

Bought it from a company in Cork.120euro for 30sq m. Easily found on google.

del88

defike wrote: »

Bought it from a company in Cork.120euro for 30sq m. Easily found on google.

Thanks...where did you buy your windows??
photos look great...keep em coming

peasant wrote: »

Before applying any insulation I would make sure that all the seams, folds, nooks and crannies where water could run into or sit in are waxoyled.

You'll never get at those areas as easily again

just watched a few vids on waxoyled...looks like good stuff...will give that a go...

Fingers McGee wrote: »

I dunno, Ducato's are just Meh to me.. I think the Iveco give more of an 'I'm Big, get outta my way or I'll pummel you' sort of feel, which I like. Pity I can't afford one though, I'm stuck with a transit. Still though...

I think something along the lines of this thermawrap would be the bubblewrap type thing.

Will be doing my own conversion soon (hopefully making an actual start next friday) so will start my own thread on how and what I'm doing then.

That thermawrap looks great ...i've seen something similar been used on a van on the SMBCC web site...

defike

Windows fridge cooker/sink from O learys campervan supplies in england.
Posted over for 100 pounds.Check their website.

Buford T Justice

defike wrote: »

Windows fridge cooker/sink from O learys campervan supplies in england.
Posted over for 100 pounds.Check their website.

CAK tanks have a massive catalogue and a price list to go with it. Worth a look, they seem to have everything. You can download both of them

http://www.caktanks.co.uk/

Buford T Justice

peasant wrote: »

Before applying any insulation I would make sure that all the seams, folds, nooks and crannies where water could run into or sit in are waxoyled.

You'll never get at those areas as easily again

Thanks Peasant.

Can these be reached with just the aerosol can? Is there a need to get the gun and all for it?

del88

Went out yesterday looking for vans.....think i've decided on a fiat ducato/peugeot boxer/citreon relay...their basicaly the same van.i'm on the look out for the maxi van version (extra long wheel base and high roof)
allthough the long wheel base version would work fine.
The big plus was the fact that the hand break is not in the centre of the cab so dosen't effect with fitting the swivel seats.
So still trying to price everything....finding it tricky to get my head around the electrical side of things.
I found one site that seemed to explain things a bit.
http://www.deepredmotorhome.com/electrics.html
Still not to sure what i need ..there seems to be lots of diffrent set ups.

looks like i need a leisure battery charger..
some sort of control panel for it (zig unit or similar)
12volt fuse board
a leisure battery
switches for water heater,water pump,
water level indicators
cable
mains inlet
mains consumer unit with rcd
sockets

thats all for now but i'm sure i've missed a few things

peasant

Fingers McGee wrote: »

Thanks Peasant.

Can these be reached with just the aerosol can? Is there a need to get the gun and all for it?

Best to do it with a long brush and sort of stipple it in. The gun is handy for where the brush doesn't reach.

pandos

Hi I bought my Electrical panel from O Leary, comes as a complete unit with ELCB Tripswitches, charger low voltage outlets fuses pump switch and battery indicator and a few more bit, I got everything else electrical wise from a wholesaler yesterday.

del88

pandos wrote: »

Hi I bought my Electrical panel from O Leary, comes as a complete unit with ELCB Tripswitches, charger low voltage outlets fuses pump switch and battery indicator and a few more bit, I got everything else electrical wise from a wholesaler yesterday.

Hi pandos
Just had a look at their web site...which one did you get??
By any chance would you have a list of everthing you needed...cheers

Buford T Justice

Aaaaaaaaaarrrghhhhhhh RATS!

I'd found a caravan for €650 today as a donor and drove about 2 hours to see it. Got there, different caravan and yer man wanted 1800 for it. Turns out he sold the one that I was after and never removed the ad from the net. Baxtard.

Feck. I was hoping I'd get it and that would have given me 95% of bits.

If anyone knows of a donor going (storm damaged, crashed etc) caravan, fairly cheap in the North West can you let me know please, I'd be interested....

Thanks, and again.... Feck!

del88

I feel your pain ....
Check out done deal.....http://www.donedeal.ie/find/all/all/Ireland/caravan?sort=price&start=30

keep the faith ...good caravans come to those who wait..

del88

Well had a look at a van yesterday...it was a fiat ducato maxi.
Not a bad van but the guy wouldn't move on the price and he had already started converting it himself and the window layout didn't suit so the search contiues.....

pandos

del88 wrote: »

Hi pandos
Just had a look at their web site...which one did you get??
By any chance would you have a list of everthing you needed...cheers

del88

Sorry no list, but if I had one it would keep getting longer.

Am nearly finished now and might make out a list when I am finished but if you are working with self use in mind then a caravan is the cheapest source, I intend to sell this one and build another identical one so only new gear is being used,

If I was starting again on a tight budget I think a trip to the UK pick up a van cheap and go directly to caravan scrapyard, buy a complete caravancut out all of the bits that are usable and bring them home in the van,

I built my first camper from a donor caravan and it was really cheap and easy.

Buford T Justice

pandos wrote: »

del88

Sorry no list, but if I had one it would keep getting longer.

Am nearly finished now and might make out a list when I am finished but if you are working with self use in mind then a caravan is the cheapest source, I intend to sell this one and build another identical one so only new gear is being used,

If I was starting again on a tight budget I think a trip to the UK pick up a van cheap and go directly to caravan scrapyard, buy a complete caravancut out all of the bits that are usable and bring them home in the van,

I built my first camper from a donor caravan and it was really cheap and easy.

Trouble is gettin a donor that has everything you want for cheap.

Not so easy really. Wonder has anyone been to caravanbreakers.net in wales?

del88

well looked at a vw crafter today...was very impressed...think i'll make an offer on monday....all very exciting

Buford T Justice

best of luck dell, its a nice van, but I'd rekon its not that cheap tho....

del88

Had a look at the crafter and wasn't happy with it...did some research on them and they don't have a good rep...
So am thinking about going back to the original plan of a ducato/boxer/relay....smaller van and might suit better then a sprinter or an iveco daily.
Off to look at one tomorrow......

Buford T Justice

del88 wrote: »

Had a look at the crafter and wasn't happy with it...did some research on them and they don't have a good rep...
So am thinking about going back to the original plan of a ducato/boxer/relay....smaller van and might suit better then a sprinter or an iveco daily.
Off to look at one tomorrow......

Best of Luck. Sprinters are reliable wagons.... Transits are good too. parts everywhere but finding a Hi Cube in good shape isn't the easiest. I had a bit of a job to get mine.

ipod

hi i have a vw crafter its a 06.realy happy with this van.no trouble with this one.

Buford T Justice

Shazam MO FO!

Managed to get my hands on a donor for my conversion. has most things that I need. Sink, Shower, Casette Toilet, Water Heater, charger Fridge skylights etc......

Interestingly, it has an odd sort of a zig unit built into it.
Even more oddly, none of the switches seem to work on it. There is currently no battery in it, and when I had it hooked up to the car nothing on the interior worked on it. Plugged it into the mains and all worked fine. Am I missing something or does there need to be a battery in the wagon for the 240/van/car switch to work?

I've not spent that much time looking at it yet but I want to check that everything's in pwo before I start stripping.

Any Ideas where I can get documentation on anything in it, like the water heater etc...?

Any help is appreciated.

paddyp

del88 wrote: »

Had a look at the crafter and wasn't happy with it...did some research on them and they don't have a good rep...
So am thinking about going back to the original plan of a ducato/boxer/relay....smaller van and might suit better then a sprinter or an iveco daily.
Off to look at one tomorrow......

I have a ducato and a relay. A commercial mechanic my father knows says the iveco engine is great and the rest of the van is a ball of s*ite. I have to agree with him on a lot of points. Look at the crash test for a sprinter vs ducato ouch. I went with the ducato for three reasons .. it was shorter than the sprinter (at the expense of safety) which made it better for town, the gear shift on the dash plays nicely with our swiveling seats, the corrosion protection on the facelift model is very good.

In terms of conversion the side panel shape is crap for installing windows, bonded windows if you can get them sit proud of the bodywork not recessed like other vans, and the curvature of the panel limits rubber fit, seitz etc window height to about 500 - 550mm.

The key issue for me is parts, there are about 4 plus times as many transits about ireland and about 8 plus times in the uk the scrap yards are full of them and spurious parts are plentiful and cheap. When you look at the scrap yards there are almost no ducatos they just get crushed after a short time whereas there are always a couple of transits haning around.

Now try ringing around the scrap yards for ducato parts. I called and emailed about 50 in ireland and the uk looking for injection parts for my ducato and ended up having to ordering from Hungary. Next time I'll buy a transit.

kittyj

Hi folks,
Just started a campervan conversion, bought a peugeot boxer, have so far planned the insulation, goin for rockwool and alububble then plywood,
Just fitted another window today so will have four in total ,
Im looking ahead to the furnishings so was just wondering if any other Boards.ie people had done a campervan conversion as any tips would be great,
On a budget so was thinking of trying to find a breakers yard in dublin and look for caravan furniture,
has anyone had sucess with this?
Mostly looking for the cupboards and kitchen unit,
The van came with a cooker/sink and a spare oven hob so goin to decide which one to put in,
Has anyone had dealings with the Dolmen Insurance crowd and the engineers report jazz ?
Any advice welcome
Thanks Kitty j Dublin

Buford T Justice

You could always buy a donor caravan like I did, and it has everything that I needed. Just dumped it yesterday.

Could well be cheaper than buying the furniture separately, and the hassle of trying to find it.

anronmor

Nearly finished my own conversion - high roof T5 transporter. Will be changing tax status next month so fingers crossed the open market price is reflective of the actual market.

Biggest piece of advice I have is that everything you put in there is going to add to the weight of the conversion and the amount of diesel you'll have to use to go anywhere in it.
If you think about it you don't need everything a factory built conversion has to enjoy using your camper

Buford T Justice

anronmor wrote: »

Nearly finished my own conversion - high roof T5 transporter. Will be changing tax status next month so fingers crossed the open market price is reflective of the actual market.

Biggest piece of advice I have is that everything you put in there is going to add to the weight of the conversion and the amount of diesel you'll have to use to go anywhere in it.
If you think about it you don't need everything a factory built conversion has to enjoy using your camper

Any pics of it?

Aidan_M_M

paddyp wrote: »

I have a ducato and a relay. A commercial mechanic my father knows says the iveco engine is great and the rest of the van is a ball of s*ite. I have to agree with him on a lot of points. Look at the crash test for a sprinter vs ducato ouch. I went with the ducato for three reasons .. it was shorter than the sprinter (at the expense of safety) which made it better for town, the gear shift on the dash plays nicely with our swiveling seats, the corrosion protection on the facelift model is very good.

In terms of conversion the side panel shape is crap for installing windows, bonded windows if you can get them sit proud of the bodywork not recessed like other vans, and the curvature of the panel limits rubber fit, seitz etc window height to about 500 - 550mm.

The key issue for me is parts, there are about 4 plus times as many transits about ireland and about 8 plus times in the uk the scrap yards are full of them and spurious parts are plentiful and cheap. When you look at the scrap yards there are almost no ducatos they just get crushed after a short time whereas there are always a couple of transits haning around.

Now try ringing around the scrap yards for ducato parts. I called and emailed about 50 in ireland and the uk looking for injection parts for my ducato and ended up having to ordering from Hungary. Next time I'll buy a transit.

jeez Paddy , I dunno , I'd still have a Ducato... IMo they're nicer to drive than a Tranny . And I've barely ever had to get anything from Fiat . Maybe they're just more popular in Munster.. especially in the Pug/Citroen (dis)guise.