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Ford Transit camper build
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Now for some mods!
The standard plastic wheel was a bit gacky so my friend pulled it out of the bag and covered it with an eBay special. Looks and feels a million times better now.
Now for some mods!
The standard plastic wheel was a bit gacky so my friend pulled it out of the bag and covered it with an eBay special. Looks and feels a million times better now.
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Next step is to run all the 230v wiring over the inside of the roof and to the various points where it'll be needed. There was also a lot of 12v wiring to be hidden too, for 12v sockets, lighting etc. The bubble insulation is added to with that scratchy fibreglass type stuff
The floor is getting bubble wrapped (cutting it out in this pic) and getting a sheet of thin corrugated plastic before getting the ply floor over that.
The floor is an off the shelf Transit floor.
The wall panels are also premade. In retrospect this is something we could have easily done ourselves. Test fitting one here.
Fitted a damp proof course (Dealz dust sheet)
Next step is to run all the 230v wiring over the inside of the roof and to the various points where it'll be needed. There was also a lot of 12v wiring to be hidden too, for 12v sockets, lighting etc. The bubble insulation is added to with that scratchy fibreglass type stuff
The floor is getting bubble wrapped (cutting it out in this pic) and getting a sheet of thin corrugated plastic before getting the ply floor over that.
The floor is an off the shelf Transit floor.
The wall panels are also premade. In retrospect this is something we could have easily done ourselves. Test fitting one here.
Fitted a damp proof course (Dealz dust sheet)
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Next job is to fit the other lights into the roof ply. The roof panel can be reused from the original minibus conversion but will have to be cut down a little to fit the new walls.
I made boxes for the lights just in case they came in contact with the insulation, which is conductive.
Test fit, all good.
Next job is to fit the other lights into the roof ply. The roof panel can be reused from the original minibus conversion but will have to be cut down a little to fit the new walls.
I made boxes for the lights just in case they came in contact with the insulation, which is conductive.
Test fit, all good.
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This was the most fiddly part.
In my infinite wisdom, I decided that it would be nice to completely box around the windows and have the ply come up to the roof, rather than the much easier gluing the wall material directly to the metal around the windows. Figured it would look more professional and neat, plus you'd have window ledges for putting stuff on, and it might make adding curtains or blinds easier.
The glass is curved too, which made this more of a pain. This will all be carpeted over. All edges smoothed off now. Same craic on the passenger side.
All cavities bubble wrapped with bubble wrap and filled with insulation. Roof bubble wrapped and insulated too. Wheel arches insulated and boxed off.
Screw holes starting to be filled and sanded. Roof partially up and wiring ran for the lights. (Will be connected to a leisure battery.)
This was the most fiddly part.
In my infinite wisdom, I decided that it would be nice to completely box around the windows and have the ply come up to the roof, rather than the much easier gluing the wall material directly to the metal around the windows. Figured it would look more professional and neat, plus you'd have window ledges for putting stuff on, and it might make adding curtains or blinds easier.
The glass is curved too, which made this more of a pain. This will all be carpeted over. All edges smoothed off now. Same craic on the passenger side.
All cavities bubble wrapped with bubble wrap and filled with insulation. Roof bubble wrapped and insulated too. Wheel arches insulated and boxed off.
Screw holes starting to be filled and sanded. Roof partially up and wiring ran for the lights. (Will be connected to a leisure battery.)0 -
Next job in is getting the 12V electrics working. This was another fiddly one, sourcing the right parts and getting everything to fit neatly. The fuse boxes came from The Range, the isolater switch and the leisure battery and one of the battery leads came from Halfords (thank you trade card!) the smaller bits like crimp connections and the cable going from the battery to the fuse box were got in Maplin. My friend got the split charge system online, the outer casing for the fuse box came from B&Q
We will have to make a bracket for holding in the second battery. The small square box is the split charger. This disconnects the leisure battery from the van battery when the engine is turned off so you don't run down the van battery. The isolater switch adds a layer of protection and should prevent the battery draining over time.
Next job in is getting the 12V electrics working. This was another fiddly one, sourcing the right parts and getting everything to fit neatly. The fuse boxes came from The Range, the isolater switch and the leisure battery and one of the battery leads came from Halfords (thank you trade card!) the smaller bits like crimp connections and the cable going from the battery to the fuse box were got in Maplin. My friend got the split charge system online, the outer casing for the fuse box came from B&Q
We will have to make a bracket for holding in the second battery. The small square box is the split charger. This disconnects the leisure battery from the van battery when the engine is turned off so you don't run down the van battery. The isolater switch adds a layer of protection and should prevent the battery draining over time.0 -
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Finally, a fun job!
You gotta have a reversing camera right? Hooray for eBay.
Specific fitment camera replaces one of the old number plate lights.
Handy place to mount the screen too.
It works, trigger for the reverse light done, just can't find a 12v ignition feed. Haven't checked the radio yet but the 2 cigarette lighter sockets are permanent live. Does anyone know if it's just a matter of swapping a fuse like it is on other Fords?
Finally, a fun job!
You gotta have a reversing camera right? Hooray for eBay.
Specific fitment camera replaces one of the old number plate lights.
Handy place to mount the screen too.
It works, trigger for the reverse light done, just can't find a 12v ignition feed. Haven't checked the radio yet but the 2 cigarette lighter sockets are permanent live. Does anyone know if it's just a matter of swapping a fuse like it is on other Fords?0 -
Second half of the ceiling finally up tonight!
Bit of sanding to do so the carpet will be perfectly smooth. The dark patches are glue from before, looks like there's a leak but there isn't -thank gawd
Ply around the window looks a bit strange in this pic, it's just black paint around the edge, looks completely crooked!
Another slightly unusual job. I am probably a bit too particular about how the carpet will sit. Time will tell if isopon was the right tool for the job here. I can't see it cracking as everything fits tightly.
Will sand it again tomorrow, but once it's the right shape for the carpet it'll be grand.
Second half of the ceiling finally up tonight!
Bit of sanding to do so the carpet will be perfectly smooth. The dark patches are glue from before, looks like there's a leak but there isn't -thank gawd
Ply around the window looks a bit strange in this pic, it's just black paint around the edge, looks completely crooked!
Another slightly unusual job. I am probably a bit too particular about how the carpet will sit. Time will tell if isopon was the right tool for the job here. I can't see it cracking as everything fits tightly.
Will sand it again tomorrow, but once it's the right shape for the carpet it'll be grand.0 -
The sockets arrived today, nice neat jobs, they're specifically for campers and caravans.
My mate also got the carpet, so I messed around with fitting some of it. It's stretchy enough, so hopefully it will stretch into the corners of the window openings.
The sockets arrived today, nice neat jobs, they're specifically for campers and caravans.
My mate also got the carpet, so I messed around with fitting some of it. It's stretchy enough, so hopefully it will stretch into the corners of the window openings.
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Didn't get to this till late this evening but next step today was making the kitchen cabinet. Picked up the worktop in the Ikea bargain corner. It's a table top originally but ideal for what we needed.
Made up the frame for the cabinet, the outer sheets will be fixed to this frame. This will house the gas bottle, waste and fresh water tanks, a cutlery drawer and general storage.
Didn't get to this till late this evening but next step today was making the kitchen cabinet. Picked up the worktop in the Ikea bargain corner. It's a table top originally but ideal for what we needed.
Made up the frame for the cabinet, the outer sheets will be fixed to this frame. This will house the gas bottle, waste and fresh water tanks, a cutlery drawer and general storage.
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Not much to report today
This arrived though
Better stock photo
Spent a good while cutting out for it, the worktop is hollow, so will be reinforcing the section around the cooker/sing with solid wood inside, basically filling in the gap. should make it cope better with possible heat and moisture.
Water cans came too.
Messed around with making the boxes at the back too, just seeing how things will line up etc.
Middle slips of timber are there just as spacers to keep things square
Not much to report today
This arrived though
Better stock photo
Spent a good while cutting out for it, the worktop is hollow, so will be reinforcing the section around the cooker/sing with solid wood inside, basically filling in the gap. should make it cope better with possible heat and moisture.
Water cans came too.
Messed around with making the boxes at the back too, just seeing how things will line up etc.
Middle slips of timber are there just as spacers to keep things square0 -
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Did a bit more work on the rear seats tonight while my mate cut the hole in the floor for the gas vent. It's a bit more time consuming the way I'm doing it, but it should have a nicer finish with no visible screw holes. Filled in the gaps in the hollow worktop too so it'll be super solid now. Also slightly damaged the worktop in my haste. Should be able to repair it handy enough hopefully.
We did a lot of planning out for the kitchen unit too in terms of drawer and door sizes, location of gas box, water cans etc, so hopefully by the time I'm finished work tomorrow he'll have gotten the door openings cut out of the front panel and we can start fitting the drawer, securing the sink/hob etc.
Did a bit more work on the rear seats tonight while my mate cut the hole in the floor for the gas vent. It's a bit more time consuming the way I'm doing it, but it should have a nicer finish with no visible screw holes. Filled in the gaps in the hollow worktop too so it'll be super solid now. Also slightly damaged the worktop in my haste. Should be able to repair it handy enough hopefully.
We did a lot of planning out for the kitchen unit too in terms of drawer and door sizes, location of gas box, water cans etc, so hopefully by the time I'm finished work tomorrow he'll have gotten the door openings cut out of the front panel and we can start fitting the drawer, securing the sink/hob etc.0 -
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My mate got the front of the kitchen CNC routered out today. Lovely tidy job to be fair.
We fitted the panels to the kitchen frame. Forgot that the supplier had given us 18mm instead of 15mm and how that would make the unit wider than the worktop. Anyway, routered out the edge of one of the side panels which should fix that.
My mate got the front of the kitchen CNC routered out today. Lovely tidy job to be fair.
We fitted the panels to the kitchen frame. Forgot that the supplier had given us 18mm instead of 15mm and how that would make the unit wider than the worktop. Anyway, routered out the edge of one of the side panels which should fix that.
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So today we said we'd do a small bit and go for a few pints. 8 hours later, still there and no pub
Made a good bit of progress today though. Started out by routering out the edges of the doors and kitchen frame to accept a hammer-in T trim. This will fill the 6mm gap left by the CNC router and put a durable edge on the kitchen doors and frame. Next I made a box to put the gas bottle into. This lines up with the hole in the floor made last week.
We also fitted the drawer and the back panel for the kitchen units, and finished off putting the edging strips on the bed boxes.
It's all coming together, not a massive amount to do.
Drawer front not actually fitted yet, need to glue in the rubber edging and stuff first.
Next jobs will be to make a door for the gas box and fit the bracket to hold the bottle in, do some 230v wiring, and get the doors hung
So today we said we'd do a small bit and go for a few pints. 8 hours later, still there and no pub
Made a good bit of progress today though. Started out by routering out the edges of the doors and kitchen frame to accept a hammer-in T trim. This will fill the 6mm gap left by the CNC router and put a durable edge on the kitchen doors and frame. Next I made a box to put the gas bottle into. This lines up with the hole in the floor made last week.
We also fitted the drawer and the back panel for the kitchen units, and finished off putting the edging strips on the bed boxes.
It's all coming together, not a massive amount to do.
Drawer front not actually fitted yet, need to glue in the rubber edging and stuff first.
Next jobs will be to make a door for the gas box and fit the bracket to hold the bottle in, do some 230v wiring, and get the doors hung0 -
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More bits done this evening.
Biggest job was putting the roof lining up. Supplier ran out of the colour we wanted a few weeks ago so we didn't do it at the same time as the walls. Worked out well I think.
We also fitted the extra sockets, made a top for the drawer, fitted the seal to the gas box, and reinstalled the units.
More bits done this evening.
Biggest job was putting the roof lining up. Supplier ran out of the colour we wanted a few weeks ago so we didn't do it at the same time as the walls. Worked out well I think.
We also fitted the extra sockets, made a top for the drawer, fitted the seal to the gas box, and reinstalled the units.
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So the RGI lad came today and did a bit of the gas fittings. We got the sockets and RCB wired up too, finished making the frames at the back except for the lids, which we will do tomorrow. Table is cut too, just needs fixing to the floor, door back on the gas box, and more messing around with the door trims
So the RGI lad came today and did a bit of the gas fittings. We got the sockets and RCB wired up too, finished making the frames at the back except for the lids, which we will do tomorrow. Table is cut too, just needs fixing to the floor, door back on the gas box, and more messing around with the door trims
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So we are 99% done. Just a few tiny bits to finish but it's pretty much ready for inspection now anyway.
Oh yeah, needs cushions and curtains obviously
So we are 99% done. Just a few tiny bits to finish but it's pretty much ready for inspection now anyway.
Oh yeah, needs cushions and curtains obviously 0 -
Didn't get the SQI inspection today, think it's Monday now.
Gave us a chance to finish a few more bits.
Some cute little cubby holes, the lids just drop in.
Abandoned the piano hinges as they were a balls. These ones work way better and hold it upright no bothers.
Have a third hinge for the middle, haven't fitted it yet. Still have to fill the screw holes with plastic wood.
Want to fit speakers too, but they're surprisingly hard to come by these days.
Didn't get the SQI inspection today, think it's Monday now.
Gave us a chance to finish a few more bits.
Some cute little cubby holes, the lids just drop in.
Abandoned the piano hinges as they were a balls. These ones work way better and hold it upright no bothers.
Have a third hinge for the middle, haven't fitted it yet. Still have to fill the screw holes with plastic wood.
Want to fit speakers too, but they're surprisingly hard to come by these days.0 -
We got a lend of cushions for the VRT photos and test.
Finished everything else too.
Having the cushions in makes such a difference. I can't get over how spacious it feels inside for such a small van.
We got a lend of cushions for the VRT photos and test.
Finished everything else too.
Having the cushions in makes such a difference. I can't get over how spacious it feels inside for such a small van.0 -
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Duke O Smiley wrote: »Stellar work as mentioned before Colm.
Did you get much use out of it during the summer?
It got a few outings, but no, there was more time spent building it than using it
There’s plans in place for the difficult second camper. Bigger and more complicated - so this one may be up for sale very soon.0 -
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