Fiat Ducato camper build

listermint

welding them up, or whats the plan ?

colm_mcm

listermint wrote: »

welding them up, or whats the plan ?

Pop rivets, non-silicone sealant in the hole first and then undersal on the outside.

CJhaughey

Thats a nice bottle holder for the gas bottle.
How are you sealing the gas locker door?

colm_mcm

CJhaughey wrote: »

Thats a nice bottle holder for the gas bottle.
How are you sealing the gas locker door?

The last time I used a self adhesive rubber seal on the door and one on the frame.

DLady

Looks so good! Looking forward to more posts.

colm_mcm

Thanks, it’s taken a bit of a back seat the last few weeks so not much progress.

colm_mcm

Did a bit more today. Cut out the ply for the ceiling



Some packers to meet the frames we bonded to the roof all those months ago


First bit of ceiling up.

colm_mcm

The last section of ceiling up



It’ll be all coming down again for the vapour barrier but it’s actually easier to do it this way.

colm_mcm

Started on the overhead locker



Right pain of a thing to assemble in sitiu

colm_mcm

So despite being one of the higher Ducato specs, the van only has upper grab handles like you’d get on your car, it didn’t come with the handles on the A pillar



My friend ordered them online, they’re OEM parts so should be an easy job. Unfortunately there are no markings on the pillar trims as to where the holes go.


First job is to fit some rivnuts into the A pillar, then measure their position relative to the windscreen


Next, transfer those measurements to the pillar trim


Drill out the trims so they’re big enough to take the handles


Luckily it went ok!

colm_mcm

Put up the vapour barrier today



Refitted the ceiling panels


And fitted the carcass for the overhead locker

Car99

Are you keeping a count of the manhours your conversion is taking?

colm_mcm

Car99 wrote: »

Are you keeping a count of the manhours your conversion is taking?

No. We would never do anything again if we knew how unproductive we are.

Tacitus Kilgore

colm_mcm wrote: »

No. We would never do anything again if we knew how unproductive we are.

Building a van myself at the moment and while I keep track of the money spent, I absolutely never want to know how many hours have gone into it. :eek:

BrunoBS

That is a very nice thread!! Started to follow it today... Great job so far... are there any news on the development of the camper?

colm_mcm

It’s been moving very slowly along, other commitments and the weather are what’s being blamed.

Muahahaha

Just came across this, great build. Have you had any progress during the lockdown? Presume you'll get it on the road for this summer all going well

colm_mcm

Few easy jobs,

Thule bike carrier fitted



Also, lock handle protectors, which are a plate inside and outside the drivers and rear door handles which stop screwdriver attacks on the handle.





Hopefully get a little more done, but CV19 not helping.

colm_mcm

First version of the gas box. All joints sealed before painting, dropout vent underneath, rubber seals on doors (which will be later swapped for lightweight ply doors and interior will be lined with trim carpet). Bulkhead regulator, large propane bottle, and tie-down straps.



Exterior of boxes are just bare ply now but will be finished in 4 way stretch carpet as in the Transit.

John_Rambo

John_Rambo wrote: »

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.

LOL... looking back at the thread and ^^ Cringing so much at my offer that my ears are meeting at the back of my head... You're obviously a dab hand at this and it looks like a thorough professional refit.

Hope the lockdown hasn't affected the work. Looking forward to the next photos.

colm_mcm

Sadly the lockdown has really affected our ability to work on the van, even something as simple as getting small supplies has a big effect.

We are still learning every day, and we are by no means experts.

colm_mcm

Not done today but still!

Made the template for the piece that will meet the factory seat belt and cab ceiling trims. This is a bit of a fiddly job (my favourite) so I’ve done a template in light ply first as the veneered lightweight ply that will be used is eye-wateringly expensive so no room for mistakes!
There is a slight curve on the bottom edge of the aperture for the cubby box too, just to be awkward.

This has the opening for the storage area over the cab too. We won’t be putting a door on this.

colm_mcm

Another fun job

CJhaughey

Bumper comes off in three pieces I think? What are you doing, timing belt?

colm_mcm

CJhaughey wrote: »

Bumper comes off in three pieces I think? What are you doing, timing belt?

It does yeah, there’s a bazillion bolts on the fecking thing!

Doing a bit of colour coding. Stay tuned!

CJhaughey

I will stay tuned, I'm interested to see how close yours will end up to mine!

Black_Knight

colm_mcm wrote: »

It does yeah, there’s a bazillion bolts on the fecking thing!

Doing a bit of colour coding. Stay tuned!

Either all white or all black. I'm gonna guess white

colm_mcm

Black_Knight wrote: »

Either all white or all black. I'm gonna guess white

You'd be wrong.

Black_Knight

colm_mcm wrote: »

You'd be wrong.

I'm gonna guess black (or at least the colour of the bumper).

TBH, the white would probably look a bit crap. Same reason I didn't wrap my front bumper white (hyundai ioniq EV)

colm_mcm

Grille/silver section in black. Everything else white.