460 minibus camper conversion

[johnporter11]

Good going Workbox. Mine was at that stage back in early February. I've now had it downrated to 3.5t with SV Tech's help, had a phone call from DVLA last week for photographs and the lady said she'd be able to process it OK. I'm now a 4-seater PLG.
After stripping out the floor and seat rails, I've replaced the rails with 38mm timber (glued in, so seals the threaded holes also). Metal floor insulated with a combination of closed cell adhesive foam and reflectix. I've retained the original subfloor and fitted 6mm MDF blanks into the seat holes (slips just under the rubber covering). My son made them with his CNC machine, if anyone's interested.
If anyone wants to se it, I'll post pics if somebody can explain to me how to do it! Damned if I work it out.

[workbox]

Yes, please post.

[johnporter11]

How did you upload your pics?

[workbox]

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See screenshots, click on screenshots to see bigger picture.

1st screenshot: See the upload tab,

after picture is uploaded...

2nd screenshot: See "Place Inline" button to insert uploaded image into forum post

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[johnporter11]

Still work in progress

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[johnporter11]

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[johnporter11]

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[workbox]

Good start, did you build kitchen unit from scratch ? Looking for similar kitchen set.

[johnporter11]

Used aluminium extrusion. I'm not much of a joiner but I can screw stuff together. All the panels are high gloss IKEA doors, some just screwed on, some hinged. But of course the trade-off here is weight. The units behind the drivers seat are full IKEA units reinforced with aluminium extrusion from roof to floor. Toilet compartment is going between the passenger seats and rear bed (utilising the opening window for ventilation). All the trim has been retained and I'll be using the roof trim also. I've unplugged the Ford cabin lighting circuit and connected it to the leisure battery system.

[workbox]

winter months, did you experience any condensation on aluminum extrusions build inside kitchen unit?
John you mention "I'll post pics if somebody can explain to me how to do it! Damned if I work it out.o" not to sure what you mean by that?

[johnporter11]

No condensation on it, no. I just had condensation on the few bits of metal that I hadn't done with the self-adhesive foam, like the perimeter of the roof light. I did the insides of the ribs (the crossbeams) by rolling up bits of reflectix and letting it spring out, filling the void with plastic bubble/foil.
The reference to the uploading, I couldn't figure out how to upload till you told me!

How is your build coming on?
What are your plans for layout and services?

I started on the toilet compartment today. Aluminium framework and IKEA wardrobe doors for panelling (I couldn't find anyone to ship full-length furniture board to me). They're 1.95m high, which will suit me OK. They also do 2.25m.

[workbox]

'
I am not actively build anything at the moment but always keen on the subject.

IKEA furniture looks very good but at the time I opted for Morlands lightweight poplar plywood, it was expensive but I bought 10 sheets which gives me discount (100 pounds per sheet) and free delivery
If I build again I would probably be looking at IKEA furniture first.

Morlands Plywood Samples

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[Rob62]

Nice project, love to see your progress forward.
I have similar campervan build out of commercial mk8.

I am sure you are aware of side plastic trims tend to water leak, worth to mention.

Hi workbox, I haven’t noticed any evidence of any leaking but i will bear it in mind..... seen plenty of sprinters with sills full of water..

[Rob62]

Nice van are you going to put a wet room in ? I’ve noticed that quirky rustic campers are really popular atm and selling well


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Hi boltrounder, yes i hope to fit a wetroom with a shower although i doubt it will get used much as we’ll be mainly on campsites, mainly get used just as a toilet, there will be a small sink in there too... I have modelled up a design for the layout in 3d.... i’ll upload it and post a link shortly. Hopefully I’ll be able to make it happen in real life not just in CAD..

[workbox]

Nice project, love to see your progress forward.
I have similar campervan build out of commercial mk8.

I am sure you are aware of side plastic trims tend to water leak, worth to mention.

Hi workbox, I haven’t noticed any evidence of any leaking but i will bear it in mind..... seen plenty of sprinters with sills full of water..

Hi Rob, not sills, behind plastic trims holes used to hold trim in place and Sooner or later it would leak somewhere, since you have stripped everything off it would be easy to quickly seal with Dinitrol 410 or Sikaflex.
Watch this video; about sprinter but exactly same for transit