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Fiat Ducato camper build

  • 19-05-2019 10:53pm
    #1
    Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭


    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,
    58396-DEB-5901-4412-8-D5-D-8-E4-BA0211-F58.jpg

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

    3725604-B-3128-4705-9178-0-FEF969-AD01-E.jpg
    B39-C2-A74-3798-43-F9-95-D3-127-AA154499-C.jpg
    A0-A5181-A-CE9-A-404-C-88-AB-FDD3-D2-E416-E8.jpg


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Comments

  • Registered Users, Registered Users 2 Posts: 34,104 ✭✭✭✭listermint


    Looks super clean that a 2017 ?


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    listermint wrote: »
    Looks super clean that a 2017 ?

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


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


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


    81577-A59-0-C25-4-E2-E-AAC4-FF5-D3622-ACF9.jpg
    8-B2128-A2-C0-F1-4-BE5-A69-E-94-A1-E0568542.jpg


    That’s better.
    3-BB3-C69-D-4-EB3-4083-9961-ACB155-D8-A62-D.jpg


  • Registered Users, Registered Users 2 Posts: 2,962 ✭✭✭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.


  • Registered Users Posts: 1,113 ✭✭✭thomas anderson.


    Subscribed


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  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.
    0-E266188-F017-4471-9581-10508848-B76-A.jpghttps://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.
    DD44-FBEB-C273-4-FCA-B690-78-A7-F1-EDE1-A3.jpg

    Much cleaning (not by me) later...
    C71-A4757-AA13-48-B2-8506-AABD8-F78-E7-FD.jpg


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.

    53-FB6-F48-0-B4-E-4-B8-F-A9-B7-D470-DE76-B41-A.jpg
    F7-B929-B9-8-FF5-4-F5-D-AA88-F5-DF4-FBD10-DC.jpg
    6-A1-D0695-3-EE2-49-B7-8-F54-A47-F5277-FCEC.jpg
    AFDE2-CBE-AF45-49-B4-9605-8-EAA91-E8-E791.jpg


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.
    225-CBF0-B-DBCC-4721-953-E-60737-A266-DEB.jpg
    I made some adjustments here and there. Went for 18mm ply.

    8-D9-B95-A7-8-C61-4-B0-B-AF9-E-AC96481-CBDFD.jpgB4868052-B227-4067-B848-47-A25608-B2-E8.jpg


  • Registered Users, Registered Users 2 Posts: 9,872 ✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.

    767-E2-D2-E-97-D6-4-FEF-87-A7-DF144-F40-BC03.jpg
    05-B5-D290-A3-F4-46-C6-ABB4-83-AB3198-E444.jpg
    Sealed all the joints with silicone and painted the inside black - just cos.


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  • Registered Users, Registered Users 2 Posts: 8,359 ✭✭✭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.

    "Very soon we are going to Mars. You wouldn't have been going to Mars if my opponent won, that I can tell you. You wouldn't even be thinking about it."

    Donald Trump, March 13th 2018.



  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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)

    E37807-DE-DA1-B-4-E02-9954-9-C3-F8195-A231.jpg
    5681-DDFC-F671-480-D-B3-F6-A58-F9-C826-E8-A.jpg


  • Registered Users, Registered Users 2 Posts: 8,359 ✭✭✭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.

    "Very soon we are going to Mars. You wouldn't have been going to Mars if my opponent won, that I can tell you. You wouldn't even be thinking about it."

    Donald Trump, March 13th 2018.



  • Closed Accounts Posts: 6,219 ✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 65,707 ✭✭✭✭unkel
    Chauffe, Marcel, chauffe!


    What electrical system are you planning, Colm?


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    unkel wrote: »
    What electrical system are you planning, Colm?

    CBE, no solar.


  • Registered Users, Registered Users 2 Posts: 65,707 ✭✭✭✭unkel
    Chauffe, Marcel, chauffe!


    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.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    Let there be light

    35344-ADF-0-FDA-443-B-B66-F-101-FCDF4261-E.jpg

    305-C0092-08-BE-4939-87-CE-E3-AC93690708.jpg

    79-F9-B062-5-E26-4-EA5-93-C2-CF5404-B232-D6.jpg

    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.
    24-F24-F9-E-6-EFD-4-D63-8-B0-D-06-C94403-FB4-F.jpg


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  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.
    7-D9167-D4-4-CFC-4220-A243-EB6-DA230-B9-C4.jpg

    6-B03-B379-43-AF-44-B3-94-CA-49-FBD2-A7-C506.jpg


  • Registered Users, Registered Users 2 Posts: 1,519 ✭✭✭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.


  • Registered Users Posts: 1,113 ✭✭✭thomas anderson.


    Can someone link to the transit job please and thanks


  • Registered Users Posts: 168 ✭✭Deminiman


    Can someone link to the transit job please and thanks

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


  • Registered Users, Registered Users 2 Posts: 34,104 ✭✭✭✭listermint


    Not insulating the floor ?


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    listermint wrote: »
    Not insulating the floor ?

    Will be. It’s not fully down yet.


  • Registered Users, Registered Users 2 Posts: 34,104 ✭✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.

    FDE0159-A-CED4-48-A1-A857-5-C743268-C687.jpg


    Finished burying the wiring. Insulation next.
    B05-D1-D75-0810-4-FE7-9642-80-CC12-F453-CA.jpg

    26-F2734-D-70-FD-4-C64-8717-6-C552-BAC7-A38.jpg
    A331-DDA7-6-BBB-45-A6-95-FB-DBF21-AB0-E949.jpg

    Also relocated one of the interior lights to inside the sliding door.
    396-AE450-EA2-B-432-B-948-F-4-C7-D98-E8943-F.jpg


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


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

    6506-F45-A-3312-49-E8-A377-57-E7-E5-D3-EDED.jpg

    CBA862-EC-FD22-49-B4-A5-D0-C337296-FDC3-D.jpg


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  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    Made a few changes to the drivers side cabinet
    796-DE426-BD70-426-B-8-DB1-CD236-EC96278.jpg

    Test fitting the bed
    E6-AB2-ED8-2-D29-45-E0-A493-0-B086275-A3-EA.jpg

    The bed frame is designed to sit in a bed, but I have replaced the frame with a reinforced homemade version. Halfway through that.
    99727-E69-51-CE-4-BE0-9-D51-75-F17-CD54733.jpg


  • Registered Users, Registered Users 2 Posts: 34,104 ✭✭✭✭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 .


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.


  • Closed Accounts Posts: 6,219 ✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 34,104 ✭✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 12,790 ✭✭✭✭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.

    482093.png

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



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  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    These are the standard types they build
    701-D77-F7-5-DB1-405-C-8073-542423255-E11.jpg


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.

    482093.png

    Is that going to be an ambulance?


  • Registered Users, Registered Users 2 Posts: 2,755 ✭✭✭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.

    482093.png

    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.


  • Registered Users, Registered Users 2 Posts: 2,755 ✭✭✭ianobrien


    colm_mcm wrote: »
    These are the standard types they build
    701-D77-F7-5-DB1-405-C-8073-542423255-E11.jpg

    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.


  • Registered Users, Registered Users 2 Posts: 12,790 ✭✭✭✭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.

    Ode To The Motorist

    “And my existence, while grotesque and incomprehensible to you, generates funds to the exchequer. You don't want to acknowledge that as truth because, deep down in places you don't talk about at the Green Party, you want me on that road, you need me on that road. We use words like freedom, enjoyment, sport and community. We use these words as the backbone of a life spent instilling those values in our families and loved ones. You use them as a punch line. I have neither the time nor the inclination to explain myself to a man who rises and sleeps under the tax revenue and the very freedom to spend it that I provide, and then questions the manner in which I provide it. I would rather you just said "thank you" and went on your way. Otherwise I suggest you pick up a bus pass and get the ********* ********* off the road” 



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  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    Unusual to have a FWD ambulance (Ducato)

    Been a bit slow on the build the last week.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.
    0-CD5-BE54-600-E-4-E52-8-EF8-F9-C3-D215-EBD0.jpg

    57-F9-B870-6087-43-A6-BFF6-0-B98-A3175-D69.jpg
    The rubber feet for the slats needed to be transplanted one by one.

    C202-D4-D4-6132-4-AA4-96-C6-257-C4-BE5-FF44.jpg

    11528-B9-B-D95-D-48-BE-8009-38-A71159-EFBD.jpg

    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)


  • Registered Users, Registered Users 2 Posts: 12,079 ✭✭✭✭Duke O Smiley


    Great thread Colm, only seeing it now.

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


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    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!


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


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

    CEB3-FB2-B-7-BBB-4573-A4-C2-564-C890949-F5.jpg

    AC3-E15-A5-3856-4-B15-88-FB-6951-B8-D5-A55-E.jpg

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


  • Registered Users, Registered Users 2 Posts: 2,530 ✭✭✭Car99


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

    CEB3-FB2-B-7-BBB-4573-A4-C2-564-C890949-F5.jpg

    AC3-E15-A5-3856-4-B15-88-FB-6951-B8-D5-A55-E.jpg

    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?


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 34,104 ✭✭✭✭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


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭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.


  • Registered Users, Registered Users 2 Posts: 73,477 ✭✭✭✭colm_mcm


    Bit more done in the walls
    EB46-E2-F9-ACFA-44-A9-A9-FD-B36-CB99186-F3.jpg


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