Fiat Ducato camper build

colm_mcm · 21-08-2020 7:57am

Snotaul Goodman wrote: »

Yourself and your buddy could start a small business in the camper conversion game judging by the standard of work here, Colm. Very impressive. Fair play to ye. Love those LED surrounds on the roof lights

Unfortunately it would make no money, I’d love to mess about with campers every day but it just wouldn’t pay unless you mass produce them, and where’s the fun in that?
Maybe once you take the planning time out of it and simplify the design you could knock them out in a reasonable timeframe. Easier ways of making a living

Buford T Justice · 21-08-2020 12:01pm

colm_mcm wrote: »

Electrical system was got from a supplier in the uk, it’s available in Ireland too though, it just suited to get it with some other parts. Other bits were bought locally, and more were just ordered through amazon/eBay, and some from online uk retailers. I used a spreadsheet documenting supplier prices as they can vary a lot.

Is that something you'd be willing to share?

colm_mcm · 21-08-2020 4:07pm

Buford T Justice wrote: »

Is that something you'd be willing to share?

If I can find it! Was nearly 2 years and 1 laptop ago at this stage. Will have a look

Buford T Justice · 21-08-2020 4:17pm

Thanks

Looks like I'll be starting my second build soon. I'd be interested to see what other solutions I can use in the build rather than a copy of the one I did previously such as the power distribution board and things like that

colm_mcm · 21-08-2020 4:25pm

Buford T Justice wrote: »

Thanks

Looks like I'll be starting my second build soon. I'd be interested to see what other solutions I can use in the build rather than a copy of the one I did previously such as the power distribution board and things like that

I saw your first build all those years ago!

Ref the power distribution system. Here is the control panel for it. It’s only temporarily in place for now till I build more cabinets

It does stuff like control lighting, shows temperature, battery level, water tank levels, controls the water pump and other bits. It connects to the other other board in the back.

colm_mcm · 21-08-2020 4:28pm

Got the bed in. This area still needs overhead cabinets but it will do just fine for now!

Buford T Justice · 21-08-2020 4:33pm

Is this is? https://www.cbe.it/en/pc210/

Looks like it takes care of the 240 charging too no?

Re the bed, how long is it from side to side of the van?

21-08-2020 5:02pm

colm_mcm wrote: »

Got the bed in. This area still needs overhead cabinets but it will do just fine for now!

Ah jaysus. The bed linen looks like something that was found in a grannys attic :pac:

colm_mcm · 21-08-2020 5:58pm

Snotaul Goodman wrote: »

Ah jaysus. The bed linen looks like something that was found in a grannys attic :pac:

It’s retro cool.

colm_mcm · 21-08-2020 6:37pm

Buford T Justice wrote: »

Is this is? https://www.cbe.it/en/pc210/

Looks like it takes care of the 240 charging too no?

Re the bed, how long is it from side to side of the van?

That’s the one. Yes it’ll charge the van battery as well as the leisure battery.

Buford T Justice · 21-08-2020 10:17pm

colm_mcm wrote: »

That’s the one. Yes it’ll charge the van battery as well as the leisure battery.

Nice. 'spensive.... but nice.

colm_mcm · 22-08-2020 9:46am

Buford T Justice wrote: »

Re the bed, how long is it from side to side of the van?

6’ 3”

listermint · 22-08-2020 9:47am

Will you be felting the rear doors. Always see this not done and see it as a missed opportunity they just transmit the cold directly inside and act as a surface for condensation.

colm_mcm · 22-08-2020 2:36pm

listermint wrote: »

Will you be felting the rear doors. Always see this not done and see it as a missed opportunity they just transmit the cold directly inside and act as a surface for condensation.

Not sure. The danger with that is that it would get wet if you properly covered it. Just the way the rear door seals are on them.

There is an option of plastic trims for the doors too. Not sure what we’ll end up doing yet.

BorneTobyWilde · 22-08-2020 2:40pm

Does the bed work that way, going across, is it long enough, can you stretch out.

colm_mcm · 22-08-2020 3:23pm

BorneTobyWilde wrote: »

Does the bed work that way, going across, is it long enough, can you stretch out.

Yeah I’m 6’1 and had plenty room. It’s a standard double bed size.
Very few other vans can fit a full size mattress sideways.

We made the walls in such a way that they have an extra few inches compared to making the wall straight from a single sheet of ply.

The panels behind your head/feet are 25mm from the outside skin of the van and they go straight up and don’t taper inwards so you don’t feel enclosed as much.

You can see here, the red line shows how bent ply would sit on the ribs. You’re losing a few inches there which make all the difference.

Buford T Justice · 31-08-2020 1:46pm

Where did you source your lining carpet from?

colm_mcm · 05-09-2020 9:27pm

Buford T Justice wrote: »

Where did you source your lining carpet from?

Not sure I’d recommend them to be honest. Bit of trouble with some other wrong stuff arriving.
The carpet itself is grand though.

colm_mcm · 05-09-2020 9:27pm

Bit more progress today
Start made on the kitchen

bigroad · 06-09-2020 12:13am

Nice job .To the other poster.The ducato,relay and boxer are the widest van out there.
Hence the use of them for camper build companies.
Saving about 2ft plus with the bed across the back of the van.

bobbyy gee · 06-09-2020 12:19am

I don't see you putting any insulation it will be very cold

https://gnomadhome.com/van-build-insulation/

06-09-2020 7:24am

bobbyy gee wrote: »

I don't see you putting any insulation it will be very cold

https://gnomadhome.com/van-build-insulation/

Literally 5 posts up

colm_mcm · 06-09-2020 7:50am

bobbyy gee wrote: »

I don't see you putting any insulation it will be very cold

https://gnomadhome.com/van-build-insulation/

There’s loads of insulation put in! It’s way back in the thread but it’s there

colm_mcm · 06-09-2020 6:21pm

Picked up this solid beech table top around 18 months ago.

Cut to size

Drill a few holes and make a few cuts

One kitchen.

Vertical divider in

There’s a lot more to come on this unit.

listermint · 10-09-2020 4:45pm

hadnt relealised there was no half step in the ducato. just looking at your entrance way.

colm_mcm · 10-09-2020 7:06pm

We’re going fitting an external step to solve that.

listermint · 10-09-2020 8:43pm

colm_mcm wrote: »

We’re going fitting an external step to solve that.

No meant more for like runner storage. Handy in the sprinter builds.

10-09-2020 10:04pm

Sprinters have double the ground clearance. They need the step.

air · 11-09-2020 6:13am

Sir Liamalot wrote: »

Sprinters have double the ground clearance. They need the step.

Double the internal floor height perhaps, ground clearance is only very marginally higher (~25mm).

11-09-2020 9:15am

Yurp. RWD.

colm_mcm · 11-09-2020 9:50am

There’s 110mm in the difference between a Ducato and Sprinter (with standard suspension) from the ground to the floor of the van.

11-09-2020 4:56pm

I must be used to seeing too many low in the water coach builds. I thought there was a much bigger difference.

colm_mcm · 15-09-2020 8:47pm

Little bit more progress, starting to feel a lot more campery inside now

Trying to avoid exposed screw heads or even exposed screw covers if at all possible.
Kinda a bit OCD that way..

Next job will be adding overhead lockers (which will cover the pocket holes on the toilet wall

) and a bit more work in the toilet/shower area

Oh yeah, we have a step now

Buford T Justice · 15-09-2020 9:24pm

What material are you using on the walls of the bathroom there?

colm_mcm · 15-09-2020 9:37pm

It’s 15mm Morland lightweight plywood.
The veneer is called driftwood.

All routered and cut edges varnished with yacht varnish just in case. We will be adding white PVC sheeting on the outer wall (the one that’s not built yet) but not on the others as all joints with shower and between walls will be sealed so the only way it can get wet is if the veneer on the sheet is broken. Because all edges are hidden either inside the aluminium profiles and knock-in edging (double lipped) or by the shower tray or ceiling, the chances of getting the ply part wet are quite small.

BorneTobyWilde · 15-09-2020 9:42pm

You should do a VW Bluebird next

So much space to work with.

colm_mcm · 15-09-2020 9:45pm

There goes my dinner.

BorneTobyWilde · 15-09-2020 9:51pm

Ah well it would your job to make it spacious luxurious, a real home from home. Imagination

Buford T Justice · 15-09-2020 10:08pm

Can't change the look of it though.

theguzman · 15-09-2020 11:37pm

BorneTobyWilde wrote: »

You should do a VW Bluebird next

So much space to work with.

Would a regular Joe Soap need a different category driving licence for one of those? Also they are big and akward, I drove back to Slea Head in Dingle this year and it was absolute chaotic with a convoy of German campers, some of which are absolutely monstrous in size and not suited to Irish rural roads at all, wheras the OP's Ducato conversion is turning into a lovely machine.

I am thinking heavily about converting my own camper for next summer, Me and my OH are thinking to do a tour of Scandinavia maybe next summer and a Camper is perfect for us, problem for me is it must be Automatic transmission meaning a conversion is most likely and we will go LHD. Afterwords we are thinking to have it shipped to Cartagena in Colombia or to Montevideo in Uruguay and do a few months on the road from the North all the ways down to Patagonia, if Starlink is a success it would allow us huge flexibility to work away from home also. Obviously we will start small first, one step at a time.

BorneTobyWilde · 16-09-2020 1:54am

Buford T Justice wrote: »

Can't change the look of it though.

That's the first thing I would change, total new format regarding windows n such. All those windows have to go, and the back door.

colm_mcm · 16-09-2020 10:44am

Those Bluebirds weigh 4 tonnes as a bus, so aside from needing a truck licence I’d say the 2.0 TDI would probably struggle a bit. Plus you’re paying extra on ferries because of the length.

Then you’d have to have your water tanks in the cabin and all sorts of other complications.

BorneTobyWilde · 16-09-2020 1:10pm

colm_mcm wrote: »

Those Bluebirds weigh 4 tonnes as a bus, so aside from needing a truck licence I’d say the 2.0 TDI would probably struggle a bit. Plus you’re paying extra on ferries because of the length.

Then you’d have to have your water tanks in the cabin and all sorts of other complications.

https://www.ebay.co.uk/itm/2009-Volkswagen-Transporter-2-5-RARE-BLUEBIRD-BUS-CONVERSION-FULLY-OPEARTIVE-PX/264765386127?hash=item3da53f2d8f:g:WtcAAOSw741fUcZl

You'd want the 2.5 TDI, I guess a lot of the weight is in all that glass, seats, rear doors. One would want to remove all that, and fiberglass the whole thing, fitting a pattern of plastic windows that is more reflective of a camper

end up with something like this on the inside

colm_mcm · 20-09-2020 2:39pm

Finally got the drawers for the kitchen

colm_mcm · 20-09-2020 9:42pm

Next job was cutting out some cubby holes and a door opening in the side of the kitchen.

First thing to do is use a hole saw for the corners

Then use the router to cut the straight bits

Same process as for the toilet door.

colm_mcm · 20-09-2020 10:18pm

A lot of campers have a flip down worktop extension at the side of the kitchen, but we wanted to do something a little different so I put the pull-out worktop on soft-close sliders, it’ll be very handy for the passenger seat when it’s turned around. It’s held in the out position by a few magnet catches.
There will be a flip-down door in front of this. We are also building in wireless charging underneath the shelf.

Still a bit of tidying up to do on this.

Buford T Justice · 20-09-2020 10:28pm

colm_mcm wrote: »

It’s 15mm Morland lightweight plywood.
The veneer is called driftwood.

Where did you get it, aside from ebay / amazon?

colm_mcm · 20-09-2020 10:31pm

Buford T Justice wrote: »

Where did you get it, aside from ebay / amazon?

You can get it from Cosy Campers in Dublin. It isn’t generally available from builders providers.

My friend was in the UK last year so got it there.

colm_mcm · 21-09-2020 1:03pm

Here is how the kitchen unit will work with sink/hob
Hob has a piezo igniter which stick down quite a lot.

colm_mcm · 26-09-2020 9:03pm

Did a bit on the overhead shelf today

Fiat Ducato camper build

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