"Campie" - Mk8 Transit AWD Campervan conversion

[Qwin]

This is the journey, converting my 2020 Transit L3H3 AWD into a campervan, or as the wife has named her “Campie”. Only had her two weeks so not even started the build yet.

We previously owned a Motorhome, a Peugeot Boxer based unit, so front wheel drive (FWD).
Me and the wife loved the facilities and moderate size (Just 6 meters long), but it weighed about 3 ton when packed. This lifted the weight off the front end and reduced the front wheels grip. It would get bogged down really easily. At festivals or when going to remote fishing spots, getting stuck was a frequent occurrence. This spoilt it for me, as I was always anxious when pulling on to grass, even fairly flat stuff, that I wouldn't get off again.

I decided to go the Campervan route, this allowed me to design a layout which suited our specific needs and possibly develop a light weight build. I considered Rear Wheel Drive (RWD) fitted with a Limited slip differential, to help in the rough and mud. I wasn't sure how much better the traction would be with this set up though. After much deliberation, I chose to go all out and get an All Wheel Drive (AWD) van. A quick look at Sprinter prices ruled it out, so that meant it was a one horse race. After a few months searching, I found this specemin about 200 miles from where I live:



I have quite specific ideas as far as layout is concerned. A double bed across the back with garage underneath is ok for couples, but what if I want to go to a festival with a mate or on a fishing trip. Two single beds is more versatile, if harder to accommodate. My initial thoughts are along these lines, with a full height storage space at the back to access the utilities and wiring, plus hoses, leads and ramps.



I'll keep this summary up do date, but if you want more detail, follow the link in my signature, to the project on my blog site and the whole story.

[Qwin]

Well, I removed the bulkhead and fixed the broken glass on the instrument panel.

[mesoiam]

Good luck with it, watching this one with interest as I get on with my own. Keep taking those photos please
edit: Ah I see you've got a blog going for it, good stuff, just a heads up the link in your sig is dead but I can get there from the top level

[Qwin]

@mesoiam
Thanks for the heads up.
I restructured the Project on my blog, broke it down into sections rather than one huge page for the project.
This broke the original link on my signature, but it should work again now.

[Qwin]

Update:
When swapping the double for a single passenger seat, can't believe what I found, Ford didn't bother painting the handbrake mounting hardware.
Sorted:



And the single seat in Place:



I hade to sort some of the roof, side supporting struts, which look as though they were used to tie down loads.
They are only glued to the roof, again all sorted, this was the worst one:

[Qwin]

Straightening the Rear Door

I noticed a gap between the rear offside door and its seal.
About 6mm in the middle, tapering off to zero about half a meter either side.
Looking from the outside, there was a large panel gap near the rear light and it wasn't just the hinge that wanted adjusting. I could see there had been a welded repair, using a straight edge, there was about 6mm more vertical curvature than the other door.
It looked as though a heavy load had slipped back and bent the door, or something was in the way when it was slammed shut. Either way it was bent and I wanted it sorted.

I bought a cheap 2 ton wire rope puller and attached this to one of the passenger seat rear frame bolts. I drilled a hole in the door frame and put a threaded lifting eye through the hole, into a 20mm thick plate I'd tapped to accept the eye. I pulled this up until the door frame straightened and made even contact with the door seal, when tension was released.



As can be seen from the before and after pictures, it worked extremely well, I now have nice even pressure on the door seal and a constant shut line that matches the other side.

[Qwin]

Rear Hinges/Tow Bar

The tow bar and ball hitch were in a rusty state, so I cleaned up/painted the tow bar. I renewed the Ball hitch with a combined ball and pin and while I was at it added a step, which will make access to the rear storage area much easier. The body coloured rear door hinges, in this case White, look strange to me set into the Black rear bumper. I sprayed the bottom pair Satin Black, to match the plastic bumpers. I'm much happier with the way this looks, as can be seen in the before and after pictures below, the rear is a lot tidier now.