Well I’ve gone & bought our next van.. although it’s not a van yet!

[Darcar]

So today we bought our new vehicle.
it’s a 2018 iveco daily 70-180. EX-Traffic management vehicle ( cone collector). with 75k miles auto,
my plan is to build a body onto it! Anyone ever done this ill be needing plenty of advice!
we are very happy with it so far. Drives very nice the deck is all plastic! & seems very clean underneath.
so the building starts now..

 

[Millie Master]

A brilliant vehicle, but my gaud that is one hell of a self building project, good luck to you and yours...........

@Squiffy or @Pudsey Bear might remember the sadly deceased members name who was a very regular and exceptionally gifted self builder when we were all on diymotorhome, he built several trailers in which to transport his static engines etc., as well as being used for his own accommodation that he used to tow behind his trusted Discovery.

He used to start with a good strong chassis and then build up from there using special thermally bonded panels.

I hope they can recall his name, because, if the information still exists, it could help you quite considerably.

Phil

 

[Darcar]

A brilliant vehicle, but my gaud that is one hell of a self building project, good luck to you and yours...........

@ Squiffy or @Pudsey might remember the sadly deceased members name who was a very regular and exceptionally gifted self builder when we were all on diymotorhome, he built several trailers in which to transport his static engines etc., as well as being used for his own accommodation that he used to tow behind his trusted Discovery.

He used to start with a good strong chassis and then build up from there using special thermally bonded panels.

I hope they can recall his name, because, if the information still exists, it could help you quite considerably.

Phil

Morning Phil.

You’re referring to Peter, went by the screen name Lister Diesel... & yes he certainly was a very helpful person. I’ve saw his trailer builds on the old forum.

We’re planning on some similar, although theses days you can buy the GRP insulated panels fairy easy & with the aluminium corner pieces I’m hoping that it’s just as easy as it sounds .

 

[MarkJ]

Awesome project! Doors and windows exactly where you want them - what luxury!

 

[Pudsey Bear]

Lord knows how much Peter spent on the trailers, as they were engineered to carry quite heavy loads, sadly most of the pictures have vanished, why do forums do that, storage is cheap, just put a link in it's place.

 

[Pudsey Bear]

Not what I'd have picked but it does look pretty good, the MPG should be interesting to know once built.

 

[Millie Master]

Are you planning a walk through from the cab?

 

[mark61]

Great looking truck and what a great project. As close as you'll ever get to starting with a completely clean sheet.

 

[trevskoda]

Build an alloy frame and attach alloy or GRP panels to it, my iveco bus is built this way.
If making a floor then use sealed fiber board and insulate before fitting a top skin, good luck.

 

[Pudsey Bear]

Some modern stuph.

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This one below might be more useful for the floor, I think this is the size that Peter used, but I think you can get 12 foot lengths not sure of max width, a truck building shop would have a better idea, that's where he got a lot of info on parts to use, AALCO was his supplier for aluminium extrusions for joints corners as caps.

10ft x 5ft 12mm Anti-Slip Mesh Phenolic Birch Plywood Sheets - Trailer Flooring | eBay

12MM PHENOLIC RESIN IMPREGNATED PLYWOOD FOR TRAILERS, HORSEBOXES, PICK UP, FLATBED, TIPPER, BOATS ETC. SMOOTH UNDERSIDE AND NON SLIP SURFACE.

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[Darcar]

Are you planning a walk through from the cab?

Hi yes I’m going to cut a walkthrough but only 1/2 the withe of the cab… going to keep the bulkhead behind the drivers seat.

 

[Darcar]

Build an alloy frame and attach alloy or GRP panels to it, my iveco bus is built this way.
If making a floor then use sealed fiber board and insulate before fitting a top skin, good luck.

We’re having the body built by a local fabricator in steel then clad in aluminium glued & riveted on.
My main concern is that it end up looking like a luton van.. but I’ve designed the box to look more like a Motorhome! Hopefully…

 

[Pudsey Bear]

Why are you doing that?

Cutting the bulkhead

 

[Darcar]

Some modern stuph.

Flooring Phenolic Boards

FLOORING PHENOLIC INSULATION BOARDS Phenolic floor insulation board is a most effective, closed cell, lower lambda insulation material with a fibre-free rigid thermoset phenolic core that can be used on a wide range of floor applications such as concrete, beam & block and timber floors. The...

insulationgo.co.uk

Anti-Slip Phenolic Resin Plywood 9,12,18mmTrailer Flooring Buffalo Board 8ftx4ft | eBay

9, 12, 15, 18mm Black Phenolic Hexa Hardwood Plywood 2440 x 1220mm (8ft x 4ft). This slip-resistant, exterior plywood has a hard-wearing phenolic film overlay chemically bonded to its surface by heat and pressure.

www.ebay.co.uk

Anti-Slip Phenolic Resin Plywood 12mm Trailer Flooring Buffalo Board 8ftx4ft | eBay

12mm Black Phenolic Hexa Hardwood Plywood 2440 x 1220mm (8ft x 4ft). This slip-resistant, exterior plywood has a hard-wearing phenolic film overlay chemically bonded to its surface by heat and pressure.

www.ebay.co.uk

This one below might be more useful for the floor, I think this is the size that Peter used, but I think you can get 12 foot lengths not sure of max width, a truck building shop would have a better idea, that's where he got a lot of info on parts to use, AALCO was his supplier for aluminium extrusions for joints corners as caps.

10ft x 5ft 12mm Anti-Slip Mesh Phenolic Birch Plywood Sheets - Trailer Flooring | eBay

12MM PHENOLIC RESIN IMPREGNATED PLYWOOD FOR TRAILERS, HORSEBOXES, PICK UP, FLATBED, TIPPER, BOATS ETC. SMOOTH UNDERSIDE AND NON SLIP SURFACE.

www.ebay.co.uk

Cheers for that… the flatbed that’s been built on the iveco is entirely plastic! About 15mm thick. So it’s never going to rust/rot. I’ll insulate the floor on top of the plastic & put down a 15mm ply floor I don’t think I’ll need it to be weatherproof inside the plastic body.

 

[Darcar]

Hi guys I’ve had trouble receiving the messages on here! But they have all arrived today!! Haha

Plenty has happened over the last couple of weeks. The bodies frame has been built.. a little heavier than I had intended. But the builder insisted…he’s used 50x50mm box. he’s now started to clad her in aluminium sheets.. I’m hoping to get it home this week! Then the fun really starts.

 

[Darcar]

Why are you doing that?

Cutting the bulkhead

I just like to be able to get from the cab to the rear without having to go out side…
We’re also going to swivel the passenger seat so it will become part of the lounge area.

 

[Pudsey Bear]

My memory thought you had a PVC, obviously seeing the drawings it makes sense now.

Carry on

 

[Darcar]

Little update…

we’re cracking on with a few jobs, 1st is sealing the roof panels before painting the roof. Then fitting the rear locker doors, I have raised the back end by 8“ just by cutting an angle into the body. Then tackling the awkward job of cutting the walkway between the cab and box, i‘m going to make up a gasket somehow to seal the 2” gap.
pretty happy with the progress so far.

 

[st3v3]

. Then tackling the awkward job of cutting the walkway between the cab and box, i‘m going to make up a gasket somehow to seal the 2” gap.
pretty happy with the progress so far.

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Works well

 

[Darcar]

View attachment 5755

Accordion Boot Rubber Material Replacement Order by Feet

Order Accordion Boot Replacement Rubber material to seal truck cab to Campers, Toppers and Audio Punchthrough. Sold by feet

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Works well

Thanks for that.. I wasn’t aware that there was a gasket made to do the job although it wouldn’t work in our situation, as the tin at the back of the van is very ribbed and the front of the box is 13mm plastic!

Anyway iv ordered some neoprene ( wetsuit material ) and I’m going to screw to the wood that I’ve lined the walkthrough with, I’ll leave it loose enough so any movement doesn’t rip it.
i was quite surprised by the amount of movement between the cab & box.

cheers Darren