Fiat Ducato camper build

colm_mcm

Myself and my friend decided last year after selling the Transit camper Build thread here that the next one should be bigger and better. The transit crammed a lot into a small space but had a few shortcomings in terms of load space and amenities.

It was obvious that it would have to be a Ducato (or Relay or Boxer) as they have a low floor, wide interior and are the go-to choice for camper conversions.
A wishlist was made in terms of spec, we wanted AC, reverse camera, the face lifted front end and cruise control. This of course made finding ones with all this difficult.
Luckily we found one in the UK that fit the bill,


himself had it brought in and registered as a van here.

listermint

Looks super clean that a 2017 ?

colm_mcm

listermint wrote: »

Looks super clean that a 2017 ?

Nope, 152. Yes it’s tidy enough alright.

colm_mcm

First job is to take out the bulkhead behind the seats. Reasonably straightforward job.






That’s better.

Dr Turk Turkelton

Can't wait to see this build having been lucky enough to have the transit in the flesh.
Best of luck with it Colm.

thomas anderson.

Subscribed

colm_mcm

The van had been ply-lined from new but it had spent a lot of its life being loaded and unloaded, so dirty boots, spillages etc took its toll especially inside the sliding door.
https://i.postimg.cc/tJnZ5pXR/225-CBF0-B-DBCC-4721-953-E-60737-A266-DEB.jpg
We took the sides off to get the bulkhead down, so the floor was next.


Much cleaning (not by me) later...

colm_mcm

Next thing is more windows. Fixed glass windows for the back doors, a fixed window for the sliding door, and a slider for the opposite side. All factory tinted so no messing.

colm_mcm

With the windows out of the way, next job is to cut a new plywood floor. The old floor made a handy template.

I made some adjustments here and there. Went for 18mm ply.

John_Rambo

Very clean van!! Lovely looking too... Nice grill.



As a non-handy DIY family we bought a Ducato RHD coach built van. The home conversion seems very daunting but fascinating and certainly not an option for us!!! I'm sure you're going to do an epic job!! You've probably checked out vans but if you want to check out our van to see how bits and bobs were done send me a PM. North bay Dublin based.


Thanks for posting, cracking project.

colm_mcm

Next job is making the enclosure for the gas. Last time we just put this under the sink, but this one is going to take a 9kg bottle, so something bigger needed. This will also form some of the support for the bed.



Sealed all the joints with silicone and painted the inside black - just cos.

Rows Grower

Just saw the Transit conversion there for the first time, very impressive Colm.

Looking forward to seeing the progress on this new project and wish you and your friend the best of luck with it even though I have no doubt ye have ye're homework done.

Keep us posted.

colm_mcm

Next up, we got these swivels (which unfortunately also raise the seat height) and some lowered seat bases (which bring the seats back down to regular height again)

Rows Grower

This is way better than that shed your man Lumen was working on, he's still at it.

That van will be finished tomorrow at the rate your going.

pablo128

I've a feeling you're almost finished and drip feeding the posts.:pac:

If not, check out the MAN tge leisure van for some inspiration.

colm_mcm

pablo128 wrote: »

I've a feeling you're almost finished and drip feeding the posts.:pac:

If not, check out the MAN tge leisure van for some inspiration.

Not at all! Last 2 posts have pics from today, still very much early days with a lot to do yet.

unkel

What electrical system are you planning, Colm?

colm_mcm

unkel wrote: »

What electrical system are you planning, Colm?

CBE, no solar.

unkel

I guess I should have also asked what is your planned usage of the camper?

I suppose for a very basic camper only used a few times a year it would not make sense installing sophisticated systems for water and power. Not my idea of a camper though, you might as well camp in a tent. My idea (or I guess I should call it ideal) of a camper is an alternative home. With all mod cons :cool:

Check out Will Prowse on YT.

colm_mcm

unkel wrote: »

I guess I should have also asked what is your planned usage of the camper?

I suppose for a very basic camper only used a few times a year it would not make sense installing sophisticated systems for water and power. Not my idea of a camper though, you might as well camp in a tent. My idea (or I guess I should call it ideal) of a camper is an alternative home. With all mod cons :cool:

Check out Will Prowse on YT.

It will be used for occasional semi long trips away (Europe), Irish campsites, music festivals, occasional wild camping. There will be 2 leisure batteries, a split charger and a mains battery charger installed so that should keep things running plenty long enough without needing solar.

colm_mcm

Let there be light







Makes a huge difference to the brightness in the back. Especially the area behind the front seats where we’re putting rear seating. There’s blinds and cover panels that’ll finish those off once we get the ceiling up.

Mains hookup is also in now, it’s got a magnetic lid so it’s much nicer to use than the one in the Transit.

colm_mcm

I also made up the box for the passenger side rear. This will house the RCD for the mains and will have storage. Just test fitting it here.
These boxes will both be trimmed at a later stage, and the wheelarch boxes sanded down so that the carpet trim will properly adhere.

glic83

Spotted this thread, so had to go back and check the transit conversion, great job, really looking forward to seeing how this build progresses.

thomas anderson.

Can someone link to the transit job please and thanks

Deminiman

thomas anderson. wrote: »

Can someone link to the transit job please and thanks

https://www.boards.ie/vbulletin//showthread.php?t=2057770094&page=7

listermint

Not insulating the floor ?

colm_mcm

listermint wrote: »

Not insulating the floor ?

Will be. It’s not fully down yet.

listermint

colm_mcm wrote: »

Will be. It’s not fully down yet.

Grand, was concerned . Floor is a huge cold sink especially with it being raised off the ground on wheels and wind flowing underneath. Would be a massive mistake to fail to do it as this stage of a build.

Put in as much as you can. Especially if this is a European trip camper.

colm_mcm

Got a bit more done today.

Dashboard has a common fault where some of the warning lights come on for no reason. It’s a fault with the cluster itself. It’s going to the uk to get fixed.




Finished burying the wiring. Insulation next.





Also relocated one of the interior lights to inside the sliding door.

colm_mcm

Did a bit more work on the cabinet in the back and started the insulation

colm_mcm

Made a few changes to the drivers side cabinet


Test fitting the bed


The bed frame is designed to sit in a bed, but I have replaced the frame with a reinforced homemade version. Halfway through that.

listermint

Totally down to you. Bit I'd put the floor insulation in now. As much depth as will allow head height. Putting it in after will have cold spots all over the place. Allowing damp to accumulate in hidden locations .

colm_mcm

Cabinets were made with the extra height of the floor insulation taken into account, we still need to cut out for drop vent, water lines and other things so insulation will be done at that stage. Floor is only sitting where it is, nothing’s fixed in yet.

pablo128

We'll be going to Silverstone this year in a new enough camper. It's actually a demo vehicle from my mates job. They build them to spec. There's a double bed at the back like yours but higher. Then there's 2 singles underneath. It has some sort of pull out tray then for bikes or surfboards. Its a Sprinter sized van. I'll try get pics if you like.

listermint

Hoping to do something myself like this over next few years. have a house restoration project going at the moment. But love seeing people do their own.

Toying with the idea of metal fabrication of some components for weigh reduction. Ideally want it to be as reasonable on juice as it can be.

galwaytt

A propos nothing in particular, we've got a bunch of these in the yard at work: step-framed (dropped) Ducato's on air suspension.....would make a serious camper base......you can see the pneumatic cylinder for the air suspension between the galv chassis rails, behind the cab.

colm_mcm

These are the standard types they build

colm_mcm

galwaytt wrote: »

A propos nothing in particular, we've got a bunch of these in the yard at work: step-framed (dropped) Ducato's on air suspension.....would make a serious camper base......you can see the pneumatic cylinder for the air suspension between the galv chassis rails, behind the cab.

Is that going to be an ambulance?

ianobrien

galwaytt wrote: »

A propos nothing in particular, we've got a bunch of these in the yard at work: step-framed (dropped) Ducato's on air suspension.....would make a serious camper base......you can see the pneumatic cylinder for the air suspension between the galv chassis rails, behind the cab.

They do build them on ALKO chassis (which is what that it). Fiat build the cab and ALKO built the back end.. ALKO build them as they are lower than the standard Fiat chassis.

However, ALKO chassis are loosing popularity with motorhome builders as Fiat are now building their own low floor Camping Car chassis (dedicated motorhome chassis and only sold to selected converters) with wide track suspension.

ianobrien

colm_mcm wrote: »

These are the standard types they build

Being a bo!!ox about it, they are not standard Ducato chassis cabs, they are the Fiat Camping Car Ducatos. They are only sold to specified converters.

Edit, the panel Van camping car still has the sliding door on the right hand side in right hand drive vans, not the normal left hand side for standard right hand drive vans.

galwaytt

colm_mcm wrote: »

Is that going to be an ambulance?

It is. Usually Sprinters, but we've had a gaggle of Iveco's of one sort or another over time, including 4 x 4's.

colm_mcm

Unusual to have a FWD ambulance (Ducato)

Been a bit slow on the build the last week.

colm_mcm

Did a bit more work on the beds tonight.

Cut down the frame I made a few weeks ago to fit the finished width of the van interior.

I used cable tray to reinforce the second frame (same process as the first one) I wanted something light and strong that wouldn’t take much space.



The rubber feet for the slats needed to be transplanted one by one.





So now the bed frame (which comes out to the door) sits on the boxes (which don’t come all the way out)

Happy with that.

(Also tidied up as it was starting to get dangerous)

Duke O Smiley

Great thread Colm, only seeing it now.

Will you be putting in a w/c or shower?

colm_mcm

Duke O Smiley wrote: »

Great thread Colm, only seeing it now.

Will you be putting in a w/c or shower?

That’s in the plans alright. Under pressure to get it on the road this year so we’ll see!

colm_mcm

Next we lined the roof with foil backed rubber stuff for sound deadening. Then some insulation slabs.





The cavities are then filled with polyester insulation wool stuff. Mainly for sound deadening. It’s not going to stop the body conducting heat.

Car99

colm_mcm wrote: »

Next we lined the roof with foil backed rubber stuff for sound deadening. Then some insulation slabs.





The cavities are then filled with polyester insulation wool stuff. Mainly for sound deadening. It’s not going to stop the body conducting heat.

Will the wool stuff not just soak up condensation and never dry out after?

colm_mcm

We have preventatively resealed all the roof seams, and are fitting a damp proof course over the slabs, so condensation shouldn’t be an issue.

listermint

colm_mcm wrote: »

We have preventatively resealed all the roof seams, and are fitting a damp proof course over the slabs, so condensation shouldn’t be an issue.

Any reason you didn't just foam those locations

colm_mcm

listermint wrote: »

Any reason you didn't just foam those locations

Ususual shape with limited access rules out the sheets, plus the wool is reversible if for whatever reason it needs to come out - unlike say expanding foam.

colm_mcm

Bit more done in the walls