Fiat Ducato Low Loader Conversion Project

[NorthernLoop]

I'm really looking forward to following this thread - I'm hoping to do the same for my next build. You mentioned in another thread that it is 2.2m wide. Is that excluding the mirrors?

2.18 is the internal space of the box! As this is wide body the mirrors fully extended must be extra 0.3

 

[NorthernLoop]

Then it was on to the internal framing for my 3 sections, bed at the front near cab. kitchen floor raised up 0.5m from van floor and then rear seating raised up as well

 

[NorthernLoop]

More framing and then also bringing the van GRP walls into my framing to stop them flapping in the wind as it's a big old box

 

[NorthernLoop]

SOOOO much sanding but still enjoying it

 

[NorthernLoop]

We have a FLOOR! Only put down vinyl floor see the look, it would be fixed at a later date. Floor base is super light 7kg per each 2.4x1.2

 

[NorthernLoop]

More and More supplies but U shaped seating coming together and planning massive 1.4m window above kitchen

 

[NorthernLoop]

So each of the rear U shaped seating has a hinge so I've got under seating storage, above that is covering with carpet as the base but of course I'll have cushions at a later date. The middle section is lipped so I can place another board to make out a double bed if required.

 

[NorthernLoop]

Then I turned my attention to my bed, put down a carpet underlay and again topped off with carpet,

Last image is my first weigh in, place your bets and I'll update tomorrow now. I was in the van and 1/4 of fuel

 

[wildebus]

I was going to ask if you were putting any windows in and then you mentioned kitchen one.

Any particular reason why you are cutting the hole(s) for window(s) after all the fittings above rather than initially?

 

[Deleted member 4404]

Re photos... If you use the picture icon (next to smiley) your pics should show as full size rather than thumbnails

Edit... I've just enlarged them all.

 

[SquirrellCook]

Unless I missed it, are you not worried about insulation?

 

[Deleted member 12559]

I am not sure about this actually.
I quite like the IKEA look, but when you add up the weight of the furniture (fortunately this is quite simple to do as the weights are very clearly provided on each item), plus some extra strenthening to all it to cope with all the movement, it can total a fair bit.

I am saying this as someone who has used IKEA furniture (basically using the Metod Kitchen range) in the last three camper conversions.
But in all my cases the available weight/cubic metre of living space was much higher than a typical motorhome, the last one being a LWB Panel Van with a GVW of 4600Kg, so I didn't have to worry about saving weight.


If I were doing a conversion on a brand new Box Van with a pretty nice budget available, I would look very much at the Extruded Aluminum system that in the US is called 80/20, but is also available in the UK under another name. That will give you a very lightweight but extremely strong frame to use as a base to build drawers in, hang doors from, and create walls on.

If weight saving is a vital imperative then the last resort for me would be utilising ready made furniture units
manufactured from relatively thick board products such as MDF. They are nearly all manufactured with weight
saving being a secondary consideration. The exception being specialist products such as Vohringer and the like,
(lightweight poplar based). So long as furniture in a mobile situation has a framed construction with secure strong
fixing points the main surface area can be made of <4mm ply or similar. 99% of the time it only has to be
able to withstand 'soft body' impact.
After converting a 'solid board van' with minimal fittings and furniture, then a Vohringer lightweight solid board
van I considered converting a van with the intention of making it as light as possible with no compromise
on the amount of furniture and fittings, so it was wood framing, plastic jointing blocks and 3.7mm 3 ply ash veneered
board. The whole conversion inc. appliances, electrics, tanks etc etc added less than 850kg on a Mercedes Vario sized van.

 

[Millie Master]

My question is with regards to the shower/loo tray, have you built in a very strong/rigid fully supporting framework to stop the plastic flexing? If you haven't engineered one into your build then you need to do so as otherwise it will crack.
Great workmanship by the way.

 

[NorthernLoop]

I was going to ask if you were putting any windows in and then you mentioned kitchen one.

Any particular reason why you are cutting the hole(s) for window(s) after all the fittings above rather than initially?

A few reasons, budget is big one, second one is my design is changing as I build so with the windows everything would be set once that hole is cut so I've left enough space and I'll build around it for the time being. I had planned 5 windows, 2 over my bed, 1 big one in the kitchen, 1 side door and 1 rear seating. However after I got my bed up there I didnt think about the bed headboard so I might only have 1 window there.

Unless I missed it, are you not worried about insulation?

I will be adding it as some point but it might now be reduced due to the weight, I was planned 25mm celotex but to cover the entire van its near 60kg. So I might just vapour barrier then add my internal wall covering. I'm going to use the van over the winter without and then make my mind up next year.

My question is with regards to the shower/loo tray, have you built in a very strong/rigid fully supporting framework to stop the plastic flexing? If you haven't engineered one into your build then you need to do so as otherwise it will crack.
Great workmanship by the way.

Shower will be secured into the van internal framing but its just a place holder now for idea/looks. Again this will be something next year due to budget

 

[Deleted member 12559]

A few reasons, budget is big one, second one is my design is changing as I build so with the windows everything would be set once that hole is cut so I've left enough space and I'll build around it for the time being. I had planned 5 windows, 2 over my bed, 1 big one in the kitchen, 1 side door and 1 rear seating. However after I got my bed up there I didnt think about the bed headboard so I might only have 1 window there.

I will be adding it as some point but it might now be reduced due to the weight, I was planned 25mm celotex but to cover the entire van its near 60kg. So I might just vapour barrier then add my internal wall covering. I'm going to use the van over the winter without and then make my mind up next year.

Shower will be secured into the van internal framing but its just a place holder now for idea/looks. Again this will be something next year due to budget

It's normally worth bearing in mind that should you have to sell the van due to finance difficulties or for some other
compelling reason that you're going to realise a decent sale price. Not to overcapitalize too much as it were. Of course
you have to do things primarily to suit your own needs.
Ebay always has plenty of half built vans for sale with thousands spent on top spec. electricals, appliances graphics LoL
and precious little on (crap) insulation or body corrosion, some definitely take a hit.

Don't forget to drill a lot of holes in those bed boards, you'll get condensation otherwise, & makes the van a little lighter!
You could PVA glue-in small wood block triangles at those frame screwed junctions, where you require more strength, costs
nothing.
If you're intending to so called stealth camp, then more windows makes for more conspicuousness.

I note that where you are spanning the full width of the van you've fitted some angled braces presumably to save weight?
If you find the surface too springy, a method of stiffening those full width joists is to screw fix at say100mm crs. some
25 mm x 2mm galv. steel straps the full length on the underside, will add a lot of strength and you'll probably be able
to remove the angled braces making the space more usable, but test first!

 

[NorthernLoop]

WHAT?

 

[Deleted member 12559]

WHAT?

Just pointing out WHAT some seem to overlook not aimed at anyone in particular, the first couple of sentences that is.

 

[NorthernLoop]

I wont be buying anyones seconds, I have my own ideas and plans. My van is a LONG term plan

 

[Deleted member 12559]

Well best of luck and happy travels you're definitely on your way

 

[Millie Master]

IMHO insulation and the level and efficiency of it is very arguably one of THE most important aspects of a vans build which is why I decided on having my van spray foam lined, ok the cost was a bit high, but the added weight would have been at max. no more than 10kgs.

I know it is too late now, but I would have had my ducks all lined up neatly in a row on a tick down list of most vitally important first and then if I had been on an exceptionally tight budget, I would have had fitted the trimmings later. OK that is my opinion, it isn't a criticism, you have gone down the route you decided to follow and I admire you for doing so.