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'95 LWB 150 minibus conversion

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'95 LWB 150 minibus conversion

Postby Nadjenka » Wed Jul 01, 2009 10:51 pm

It's about time I started my own post... I bought this minibus as my very first van (even though I have driven several of them in the past, never had my own :roll: ) and decided that I am going to test my abilities and convert this into nice campervan. Originally I planned to test the van properly and go on Euro tour this week, but situation has changed, trip got cancelled so here I am. Started with this:

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Pictures are taken with my mobile phone, so they are not very good, but the floor at the back has proper steel railings for seats and it had old smelly lino stuck in between

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Got rid of the seats from the back, send dear Lola (oh - that's her final name :wink: ) down to garage to get all the motor parts sorted, speedo, new cambelt, seals, filters, oil, suspention on the passengers side (because the tyre there was down to bare mesh only on the outer side :? ), ignition barrel, speedo again, and bits and bobs that were needed for me to be sure it's safe for me to drive her. :D It might sound stupid, but I am absolutely unable to even change the wheel on my own... :oops: :oops:

Lola arrived after complete check up and since I am not taking her to Europe, I can spend the time converting. I have started with locks. All of the locks needed different key, so carrying my key bunch to work felt like I own four transits, not just one... :lol: After checking flee bay and others, I decided it will be best just to drive down to Ford dealer and get advice on what I need from there. Well it wasn't such a wise idea at the end, as you could read in technical questions, but I did manage to exchange all of the locks thanks to you guys and it's now all on one key :mrgreen: (except for ignition - I will do that later as it will need reprogramming the immobiliser for new key).

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I also bought central locking kit (Maplins, for about £24), for all four doors which I fitted onto doors already but I didn't get myself to connect them yet :oops: . I am scared of electrics :roll: , so I figured I will deal with electricity questions once I start fitting electrics into the back too and I can do all of the wiring at the same time. :wink: If it's the electricity that should kill me, let's leave it for the end :lol: :lol: I will make some pictures of the central locking for you when I'll do the wires.

Then I removed existing flooring... well I intended to remove it all, but... After removing layer of thick lino, I found a layer of thin plyood. Removing that revealed another very thin layer of plywood (if you can call it that! It was the thinnest ply you have as a back side of your Ikea wardrobe... horrible stuff :evil: ) which was not only screwed, but also glued to proper layer of plywood at the very bottom. All these layers were just in between the seat rails and rough count of screwes taken out during demolition was about 170. :shock: I didn't expect that! it turned out that the iron railings are screwed and plated to the base of the van THROUGH the last and proper ply layer, so by removing them I would create loads of holes in my floor :? :? . Therefore I have decided to leave the rails there and sacrifise 2cm of head room for the plywood that needs to stay underneath the seat railings. :cry: :cry:

I filled the gaps between the rails with Depron insulation for laminated floors, and then used another layer of Depron to cover the whole floor space even over the rails so there is no iron-laminate contact. AND layed my laminate flooring :D

Image Image

You can see the rails on ply on the bottom right. You also see that I didn't cover whole floor space with laminate, and I will explain why in just a moment :wink: . During demolition works I also found out (thanks to you guys! :wink: ) that my back heater is connected directly onto the cooling system and proved impossible to remove :evil: I had to drain the system to get it shortened because there was no way of stopping it from leaking and you can imagine that being showered by cooling liquid whilst lying down underneath the van is not something you would enjoy... :evil: :evil: Originally I wanted just a simple cupboard at that end of the bus, for portable toilet and basic storage. But since I discovered that back heater (Matrix?) and two holes for it's pipes to run them down underneath the floor, I decided I will dig in my wildest dreams and build a wetroom in my bus :D :D I know, I know... I read and heard all of the cons of water in trannies and rust issues, but still - being a wild child, it would be nice to have emergency shower I can use if the wind blows me far away from civilisation and campsites... :) Do you remember that weird cut in the laminate floor? Well here is the reason:

I decided, I am going to create a fully waterproofed shower cubicle with proper showertray and drain which can be used in emergencies and sealable from the bottom so rain water doesn't get in while driving. I am going to do this using waterproofing insulation boards and paint-on tanking system, because they are giving me double waterproofing for that cubicle, insulation value and yet remaining under 5kg of weight in total. After adding tiles on that piece of the floor, total added weight should be still less than 10kg. That radiator hole in the floor will be enlarged slightly to fit low profile drain through which will have screw-on cup. After removing this cup, I can screw on flexible extension pipe to external waste tank should the need to use the shower arise. :wink: Water from the inside will never even get to the metal bits of Lola and the drain pipe end will be sealed all around from the underneath too so no water gets through the hole to the inside. It is more difficult to describe it than actually do it... :lol: :lol: I know it sounds like totall bonkers, but that's the plan and challenge... 8)

I have ordered paint too, as there is quite few rust spots coming to the surface, so I thought I'd better get it cleared and sanded off before it bites too deep and paint Lola custom very light olive green. At least I hope that it will be as light as I imagine it from seeing it on the screen :lol: I can see you all laughing at me at the next meet when I turn up with some colour rainbow on my bus... :twisted: I also want to have all fixtures removable, because of the age of Lola, there might be more and more rust, welding required and it would just be easier to be able to remove the interior fairly quickly. I am also going to have 12V underfloor heating under the laminated floor, which will be fitted after I test-fit the bed and kitchen cupboards, so I don't drill through the heating by accident during fitting... :( And - of course - this will be wired at the later stage with the rest of the electricity. :wink:

I apologize in advance for grammar, spelling and technical-terminus mistakes I might make, I am a girl and until three weeks ago the only difference I saw between vans was that some are white, some are blue and the rest is coloured... :oops: :oops: :oops: Well, here we go... :wink:

BTW: Andy, I am advancing already! I can add pictures now, see? :lol: :lol: :lol: :lol:
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: '95 LWB 150 minibus conversion

Postby MattBlackMinibus » Thu Jul 02, 2009 7:13 am

Underfloor heating :!: Wet room :!: Olive green :!:
This camper is going to be fantastic Nadjenka 8)

Don't be scared of 12v wiring,
use big enough wire, and plenty of fuses, and it will not kill you :lol:

Can't wait to see more progress,
you are getting on with it quite quickly,
and researching everything properly :D

Good luck :wink:
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Fri Jul 03, 2009 8:52 am

MattBlackMinibus wrote:Underfloor heating :!: Wet room :!: Olive green :!:
This camper is going to be fantastic Nadjenka 8)

Don't be scared of 12v wiring,
use big enough wire, and plenty of fuses, and it will not kill you :lol:

Can't wait to see more progress,
you are getting on with it quite quickly,
and researching everything properly :D

Good luck :wink:


Thanks Matt, it's not going as fast as it seems though... :lol: For me it already looks like neverending story, but I am still really enjoying myself, so it's fun. Finished my wall insulation yesterday, I'll make some pictures and new post today or tomorrow. Wait for it :wink: :wink:
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: '95 LWB 150 minibus conversion

Postby Breakdown Biker » Fri Jul 03, 2009 11:54 pm

Great ideas Nadjenka, 8)
I'm looking forward to seeing your build progress
Keep the pictures coming and good luck with your build
Awrabest!!
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 12:02 am

Breakdown Biker wrote:Great ideas Nadjenka, 8)
I'm looking forward to seeing your build progress
Keep the pictures coming and good luck with your build
Awrabest!!


Thanks, I'm still coughing out fibreglass after insulating the walls yesterday... :roll: :roll: I was just looking at your welding thread actually as I have been underneath my van today too and I have to tell ya I have seen some weird stuff :lol: :lol: Have to investigate this rust thing further because I just got mine panels all cleared and primed (no welding at this stage though) and I am going to do the painting tomorrow! :twisted: I always finish up when it's dark outside, so no pics, but I'll take some after I'm done with the paint so you can have some laughs... :wink:
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Re: '95 LWB 150 minibus conversion

Postby Luke » Sat Jul 04, 2009 10:40 am

i'm putting (well planning to) a shower in mine - it's not full height be it'll be ok for emergancys - we'd have to sit down to shower :D it was the last job i was doing before i stopped work on it for a bit :) link to my thread here i was going to line toilet/shower room in the polypropoline shown in the thread but i cant find anything to seal the edges everything just peals off :? - so i might have to use something else :? to stop moisture getting in the van it'd be fully sealed and have an extraction fan in the top :D
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 3:08 pm

Well it hasn't been a very good day for me and Lola :( After getting the panels ready to be painted I started to do the same on arches and steps and look what I found :cry: :cry: :cry:

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Basically the a***hole who sold me the bus has filled EVERYTHING with filler and painted it with several coats of hammered paint :x :x I saw couple of bubbles and trying to get them of and sanded, rust and mor rust started to appear and now it feels like the end of the world... :cry: :cry: That's just one side of the bus, poor thing. You can see it in these pictures that you don't see anything and then you dig and scrub and voa la

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I wanted to wait with welding until I get home so my grandfather can sort this out for me, but now it looks like I have to do it myself asap. Any good soul out there who can show me how to do welding? I am reading about it but it would really help if I can see how it's done in practise... :cry: :cry: Hope I don't have to remove the whole thing...
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 3:24 pm

Luke wrote:i'm putting (well planning to) a shower in mine - it's not full height be it'll be ok for emergancys - we'd have to sit down to shower :D it was the last job i was doing before i stopped work on it for a bit :) link to my thread here i was going to line toilet/shower room in the polypropoline shown in the thread but i cant find anything to seal the edges everything just peals off :? - so i might have to use something else :? to stop moisture getting in the van it'd be fully sealed and have an extraction fan in the top :D


Mine is going to be "sitting" one too, because I don't have high cube, so tall people like myself will either have to loose their head or sit down. But I think as emergency shower it is suffiecient enough. I am using waterproofing insulation boards for the floor, walls and maybe the ceiling too, haven't decided that yet. These boards will be replacing the side panels and the corners will be waterproofed with paint on waterproofing system (not sure if I can name brands... :oops: ). It's light weight, flexible, easy tu use and remowable as a whole panel - given that each time I remove the shower unit I will reseal the joints. This is the stuff

Image Image Image

That's just a sample I'm holding to give you an idea. I like this solution, because I don't have to think about any additional insulation for that corner and those panels are ready to receive lino tiles, or wallpaper or paint... Simple things rule the world. :wink:
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 5:44 pm

With breathing difficulties I got myslef to remove the back bumpers. Theeere it is... as expected :evil: :evil: :evil: Here you see thick plastered filler painted roughly, I would cut the hands off of this guy... :cry:

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And then I removed the other side... well removed... When I realised the whole thing is holding onto the body with SILICONE I sort of knew what was coming

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:cry: :cry: :cry: :cry: :cry: At this point I found myself literally crying... :cry: :cry: :cry: B@st@rd trade seller and silly me trusting the MAN!! :evil: Now I have to get the welding training because this can not be ignored. :( Can you see from that picture that it all started with a screw hole?? If only that was painted BEFORE the screw went in and was left there to rot. :cry: Poor Lola... I have a see-through filler transit. Do I replace the whole arch or do I weld it? Anybody has any advice?
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: '95 LWB 150 minibus conversion

Postby Luke » Sat Jul 04, 2009 6:04 pm

it might look bad but dont worry too much :| none of that is structural and you can get panels quite cheaply for the transit :D

have a look through beevers website (theres a link from the banner in progress section) and price up the bits - depending on the rest of the arch you might be able to patch it - but the bit behind the rear wheel arch and the sill - weld new panels in :D
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 6:12 pm

Luke wrote:it might look bad but dont worry too much :| none of that is structural and you can get panels quite cheaply for the transit :D

have a look through beevers website (theres a link from the banner in progress section) and price up the bits - depending on the rest of the arch you might be able to patch it - but the bit behind the rear wheel arch and the sill - weld new panels in :D


I am worried that I see only the bits that came through the paint. And there is much more which I can't see. I didn't remove the drivers step yet. Still can't get over what was on the passenger one :cry: . That's why I would like to meet someone who has seen loads of rust to look at it and tell me what needs to be done and if there is any more of it in places I can't see. On one side I can see there has been welding done but only from the top, the bottom is like a paper. I have no idea how this works and what it should look like...
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: '95 LWB 150 minibus conversion

Postby MinorMatt » Sat Jul 04, 2009 6:27 pm

I have to say none of that rust is the end of the world... You didnt see my passenger door step at the ACE did you? I stepped on it and it collapsed!

The problem with transits is that they rust :twisted: badly.

Have you got somewhere you could weld (bright light etc) without people complaining? Its a bit of an aquired skill but once you get the hang of it its not hard
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 6:32 pm

MinorMatt wrote:I have to say none of that rust is the end of the world... You didnt see my passenger door step at the ACE did you? I stepped on it and it collapsed!

The problem with transits is that they rust :twisted: badly.

Have you got somewhere you could weld (bright light etc) without people complaining? Its a bit of an aquired skill but once you get the hang of it its not hard


I do everything at work. Well not whilst I am actually at work, but afterwards I get changed, gloves on and I work on the tranny in front of our warehouse. Nobody is here during the week after 6pm (except for the security) and there aren't any residents around if that's what you are asking. We also are corner warehouse so I guess it would be doable here. I didn't see your passenger step :( Did you fix it already?
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
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Re: '95 LWB 150 minibus conversion

Postby Nadjenka » Sat Jul 04, 2009 6:35 pm

BTW Matt - I unplugged the tacho and plugged it back and then used your key again to unlock and lock and it works now :lol: Thanks very much for that! I also sorted out that radiator by myself at the end because no car mechanic available around here!!! They all have too much work apparently... I fixed the pipes in the engine rather than at the back of the bus and that now works too :lol: At least something went well... :roll:
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1995 Mk5 150 LWB Minibus - camper-to-be - Lola's story :mrgreen:
1999 Mk5 190 LWB 2.5TDi, automatic, story has started :twisted:
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Re: '95 LWB 150 minibus conversion

Postby MinorMatt » Sat Jul 04, 2009 7:13 pm

Nope...

I will go take a few pics of my rust - which I will be sorting soon.

Might make you feel a bit better!
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