My Self Build

[Pudsey Bear]

092 59a outside of cassette access with painted ply infill panels, I filled the door in with a 20mm thick
polystyrene to stop the cassette contents freezing 2013-05-31 11.54.33



093 59b modified rubbing strip, used old plastic internal panel linings to make a new reshaped top,
not got new clips yet hence foot holding it up for the picture

094 60 a shower plumbing under floor B&Qs finest 32mm domestic 2013-05-31 11.04.34


095, 61a have to do this before fridge housing can be fitted, it's the off side rear corner carpet and wrapped
corner panels, this is where the sofa/bed is going 2013-06-10 15.04.47


096 61b window surround etc all carpeted 2013-06-10 15.04.46


097 63a wrapping the back panel which goes behind the seat cushions 2013-06-16 11.02.16


098 63b wrapping back panel 2 Spray adhesive came from Megavanmats, good stuff sticks like you know what,
only 5 mins drive from me





100 64 a first part of fridge plinth, all pinned and glued, this was so the bottom fridge vent could clear the rubbing strip 2013-07-06 11.31.55


101 64b service holes done and 32mm waste for a gas tube so gas is isolated from any possible shorting to electricals, slots in holes are for the gas drop out vents to be efficient should there ever be a leak as this was going to be sealed to the vinyl floor covering (harrisons Cleckheaton) 2013-07-06 15.24.43


102 64c other side 2013-07-06 15.25.00


103 64d 2 large tube for blown air, the other for water pipes and cables, 2013-07-06 15.34.13


104 64e showing cutouts to allow any leaks to pass, it will of course be the other way up 2013-07-06 15.34.29


105 67b plinth for fridge, drop outs done and meshed, Flex is for the 240v fridge socket. Not sealed to floor yet 2013-07-10 16.00.53

 

[Pudsey Bear]

106 67a fridge in situ no housing yet, hopefully you get the idea now of the plinths complicated build 2013-07-10 17.58.50


107 67c fridge plinth sealed to the floor, lower vent to fridge, shows gas leak passage as there are tww drop out vents diagonally oppposite so whatever angle we're at it can escape 2013-07-11 13.17.19


108 67d top vent inside 2013-07-04 14.38.18


109 67e Fridge sides fit spot on, fridge pushes against P shaped seals at top bottom and side to make a gas tight seal, not that it matters as it is heavier than air, but it also eliminates a draught point making, the over shelf next, note Cider, I wish the fridge was plumbed in I know what
it'd be full of right now, 28 degrees outside 2013-07-13 15.18.10



110 67f supports for shelf over fridge, and makes it flat topped too, note gas escape point for the top, allows gas to flow down back or side of fridge to floor drop out vents 2013-07-16 12.21.46


111 67g shelf fitted step is to accommodate the upper vent which is slanted at 45
degrees to allow hot air out 2013-07-16 14.06.16


112 67h back boarded up 2013-07-16 14.38.51


113 67i almost done, not too happy with the diagonal cable route cover, top of pic not sure if I have enough ply to
make another so on the snag list for later
You can see KD fittings these allow me to fix the side tops to support battens above the ceiling fitted
early on, but not pictured. Notice that I have cleaned, prepped and painted the fridge satin black, I did this as the oven is black as are the Smev sink and hob covers, I replaced the silver door liners with matching 3mm ply so it all tied in, I couldn't do the knob section as I couldn't find the right decal transfers, I think it looked the bizz once all done.2013-07-16 14.40.05


115 68a top fridge vent fans (Pc 12v 100mm) temp wired to check flow direction and output, they'll help the fridge to work more efficiently in hot weather, note the yellow wires are not used so can be cut off, I wired them so I could have 1, 2 or all 3 running 2013-07-20 11.35.29


117 68d fitted in top of top vent, to suck out the hot air, simple fitting from outside,
so if I need to work on it when away, easy access 2013-07-20 12.24.08


118 69 Cleaners day off, Loo, wardrobe, fridge, and off side bed base all roughed out,
Just started on the bed base other side


119 70a start of Carver fitting. Part of rib and foam removed, template stuck up and hole drilled
for exact location on outside,2013-07-27 15.02.04


120 70b outside drawn line around template after using drill bit to locate the template in exactly the right place
and start of cut 2013-07-27 15.19.05


121 70c notice minimal marking with no sole plate on the jig saw, also = no trapped swarf to scratch
paintwork 2013-07-27 15.19.33-2

 

[Pudsey Bear]

122 70c Carver offered up, prior to last fix I replaced all the valves and seals as this would live under
the oven and although you can get at it, I preferred to plan ahead so I didn't have to 2013-07-27 15.25.41-2


123 70d Carver offered up 2013-07-27 15.25.49-1


125 70f Carver from outside 2013-07-27 15.26.13-2


127 70h Internal support frame for Carver, made from scraps of treated timber 2013-07-27 16.29.04


128 70i one of our cats Rio, giving me the evil eye as I'd woken him up cutting out for the Carver


129 71a, just a general shot from the rear. Nearside bench roughed in, note collection of green B_Q tapes,
I have dozens, and home made square etc 2013-07-26 15.36.19


130 72 mock up of phase 1 of 3 upper lockers for making an end template, clamps are to help PU go off 2013-08-03 13.54.39


131 72a mock up of phase 1 of 3 upper lockers to test the strength etc 2013-08-03 13.54.11


132 72b face frame two knocked up this morning identical (almost) 2 the one behind, I could have used a
single piece of board for these, but that would have used a full sheet, whereas doing it this way with offcuts,
biscuits and brackets and glue, it maybe cost £20 instead of £85 2013-08-08 12.16.41


133 72c Mock up for worktop height n depth using a old wardrobe door Glove for eye protection, note that
the missing bit, I used it for the gas locker door, but it gave me a nice design for the lounge kitchen divider,
do a simple drawing to have minimal waste 2013-08-07


134 72d the top of the end panel in the last picture, all biscuit jointed and glued in place waiting for the glue to go off
& offer it up and trim it to fit, you can see the join, but only about 20mm of it,
I can live with that 2013-08-08 11.16.58

 

[Pudsey Bear]

135 72e kitchen partition in place, screwed only for access if needed later. lockers up and doors (£15 each @ Magnums) on, note cut off from worktop (see later pics) used as splash back, only 12mm thick, Formica faced wallboard, came from Magnums in Beverly, they had loads 2013-08-11 15.24.05


136 72f partition and lockers from other side, I made good use of tins,
cups and plates etc to give nice repeatable radii for the corners, for the big radius
I used the door edge itself and a 15mm thick spacer 2013-08-11 15.23.16


137 72g I have to put another locker here somehow, this is partially over the SLD so
nothing to mount to below the roof rail 2013-08-08 16.24.35


139 75a over door locker support made from a bed head post from Freegle,
a good source for free stuff and wood for other jobs 2013-08-12 14.08.39


138 74 total chaos stuff everywhere, doors need to be made and or fixed, but out of the way to
prevent surface marks 2013-08-08 12.17.05


140 75b locker support, side door and beginning of over door cubby hole, Carver control will
live up here to later 2013-08-13 17.40.25


141 75ba bottom of side door too wide to get it all in closed, I need to box in the white bit on left,
but it'll never be seen when bases are in place 2013-08-15 11.14.35



I repainted some of the recycled handles and lights when I was painting the fridge parts





146 75h see some stuff I do actually works 2013-08-15 11.15.16

 

[Pudsey Bear]

148 75g back to doing lockers, long shot 752013-08-15 11.15.05


149 75k inside end locker panel at rear of van made out of 18x18 off cuts immensely strong.


151 75m locker structure, I used 10mm 6 screws into the plastic corner molding and Stixall, no movement after
two days with 40kg in each one S2013-08-15 11.51.28


153 locker fronts all made up, no pics of construction, just T joints using biscuits and glue
See next pic of adding biscuits for hinges 2013-08-15 15.20.51-1


154 76 Biscuit glued in place, these were then cut flush, and pilot drilled to accept the locker hinges,
I pre drilled them as the doors although light were quite awkward to handle, pre drilled meant the screws
went in easier. 2013-08-15 11.39.00


157 76c other side does show construction, actually just glue, biscuits and plates, belt and braces as I did not
want them to fall on my head, the LEDs came from Ebay, dirt cheap, I temp fitted them with duct tape, but
they didn't move, so left them like that, although they did have fixing holes 2013-08-15 11.42.02


159 76e just to shows problem with the hinge screws in T slot it forced them out of position, hence
retro fitting with the biscuits 2013-08-15 11.57.55


164 77a Back to the horrible over SLD locker, working in thin air, making a template for the locker rear & end panel,
a real cow of a job, very heath robinson to get to where I need it to be 2013-08-16 13.55.35


167 77d rough ply to make a second stiffer template, and continue adding bits until I was happy
with it as this would be seen a lot, sorry, no pictures of the finished end panel to post



185 80e fitted and tested, note shelf below where TV will be for cups etc, Screws will get covers, offset
is due to cushions, you don't see the TV bit when TV is in situ, I made my own vesa mount, not a complex job, but if you want more pictures of this please just ask.2013-08-29 11.30.09

 

[Pudsey Bear]

212 Top set out for Smev hob and sink holes to be measured and cut 2013-09-14 17.21.29


Back doors.

Carver Cascade 2 control 2015-06-13 16.11.34


Kitchen front 2000 2014-08-28 15.46.40


Kitchen tap Ebay special reversed handle so it doesn't get caught accidentally 2015-06-13 16.11.24


right side of interior


Switch for over cab cupboard lights and water gauge 2015-06-13 16.12.09


Truma control and stat 2015-06-13 16.11.42


Water tanks Fitted by Shaun at Tanks.me20131220_111015










Worktop

 

[Pudsey Bear]

That's about it, I have left out a few pictures as they are similar or of the same thing from different angles but there is the dropbox link to all of them plus some PDF files of interest.

If you would like to build one and are scared stiff, well so was I. I had a little 12v knowledge from fitting radios in cars, a little plumbing knowledge from general home DIY, and I could happily wire a plug, but I can read, and I can watch Youtube and I can ask questions here https://www.diymotorhome.co.uk/community/ it is free to join and there are no stupid people on there, so go have a look, it's mostly self build chat so not really competition for homers any more than my own forum would be.

I am now 67, 63 t the time of building it, and far from fit at that time, but it has been one of the most enjoyable things I have ever done, and the most frustrating at times, mainly on the 12v sparky stuff as I am truly thick at that, the 240v is easy with common sense, I would love to do another, but my health is much worse, but if I can help in any way, jsut ask.

https://www.dropbox.com/sh/yk0myzgzuz1m7n8/AAAOFzs51BoINp100lyH2KVWa?dl=0

 

[Deleted member 11]

Thanks for sharing the pics Kev. We converted our Master and, like you, enjoyed doing it. Don't think it is ever finished as we keep adding and altering minor things.
Well done.

 

[Pudsey Bear]

Liz decided it had to go due to quite high mileage, we bought it at 120k sold it two years later with 160k on it, ran like a dream, lovely to drive, and did 35 ish mpg if driven steady enough, Ben a lad from central London bought it and has done tens of thousands of miles in it since :Tears_of_Joy_Emoji::Tears_of_Joy_Emoji:

We started out with a 2003 Movano, it broke down, then we got another, it broke down, so we thought enough of these, and tried to find a Ducato, no chance much cheaper with a Citroen badge on it.

 

[Pudsey Bear]

I did a sort of blog on facts which might help, not sure if Phil would allow me to post it on here or not, I'll wait for permish.

 

[Tezza33]

Thank you for that, I thoroughly enjoyed reading it and you have done a fantastic job

 

[Campervanannie]

Great read fab conversion very talented .

 

[Exwindsurfer]

Kev that’s one great job you have done there mate .just reminded me when I done my Citroen 5years ago the only things I done differant was an underslung gas tank and a compressure fridge which I an well pleased with so get out there and enjoy yourself .

Jeff

 

[trevskoda]

Fantastic and i loved looking at every picy,i have also looked up on the window insets you gave me the link to so i know what im after but longer .