Register Login
endrop - for all your online needs
Reply
 
Thread Tools Search this Thread
Old 04-06-2020   #1
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Hey everyone.

Well a year or so ago my brother and i had the idea to get a van to convert into a camper. so we bought an Iveco Daily mk4 (2008). this was a refrigeration van. when we took apart the back of the van it had rather nice 50mm XPS insulation that we ended up recycling with much spare left over.
cut to a few months back, we still have the Daily which is still in the conversion stage but im enjoying it that much i want my own van. so i start looking at small vans. i originally was looking for a Doblo XL but i wanted something a little older, without advanced ECUs and emission controls. i went looking on Gumtree and saw this van for sale very cheap. i decided to go and have a look.
he told me it was being sold with faults. somehow over night it was draining its battery, and it over time started lacking in power. the chap had it in to a garage and they told him that it needs a complete new ECU to fix it. he was retiring from his self employed gardening business so the van was not needed as much as it used to be. fearing the cost of a replacement ECU and other faults that needed fixing he decided to sell it.
he also told me that he had the van a good 10 years or so and he religiously serviced it each year even if it did not clock up the required service mileage. on checking the dip stick i have never seen an engine so clean internally. not one bit of tarnish and the oil still a nice pleasant honey colour. little to no blow by and no noticeable oil leaks. Very Impressive.
on that i bought it.
i now was the registered keeper of a 2005 Dispatch "Enterprise 900" HDI with 99k miles on the clock for 325 with 12 months MOT.



my plans:

first off i wanted to install 2 extra seats to the van to make it a 5 seater. (more on that later!)

now i have some interesting wild Insane plans for this van. i love electronics. i cant help myself. so heres a little list of what i plan:

i plan to cram in a 48v leisure system to this van. the main component will be a heavily modified hacked and slashed 48v backup UPS (an APC SRT3000RMXLI)which will pretty much do everything for me. already having a mains charger built in, it also has a built in inverter at 2.7kw and being a UPS, if the electric hookup power fails, it will instantly switch over to battery power and keep all my 240v stuff working.
i will be using a "wind turbine" controller that i will use to tap directly into the alternators 3 phases to charge the 48v battery bank which i plan to store under the van in the gap the spare wheel usually hangs. ill be using gell cell / SLA, but if i can get my hands on some tasty AGM batteries i will use those.

the solar photovoltaic array i plan to have is also going to be pretty insane:
i plan to have a lot of solar power. i will be using a full sized roof rack on this van (that i may extend a little over the windscreen), and on that i plan to have a large roof box for storage (maybe 2) and maybe the spare wheel (though i may mount that to one of the rear doors). i plan on covering the roofbox(es) with semi-flexible solar panels. ive calculated that i should easy get 5x 18v 30 watt panels per roof box. each roof boxes solar panels will be linked in series so should get a nice 90 volts. if i do get another roof box i will add it in parallel to give my twice the amps output. i will then feed it into a Victron solar charger.

if that was not enough!
i will also have large pull out solar panels. these will be dual use. not only will they be able to be pulled out from under the roof rack for extra power, but they will also double up as a rain cover above the doors. i even have the plan on making them "push button deploy and retractable" using DC actuators. this however is something to do at my leisure as its more for "showing off"
im unsure of the total amount of watts all the panels combined will give but when the van is parked up at home it will be fed into our home self built solar array and power the house.

it does not end here however.
the van will also have a pressurised water system using a pump and bladder tank, both hot and cold running water. i will be using an old office drink water dispenser for the heating system. which has 2 modes, a 300w "instant heat" mode and a 30w "keep hot" mode where it stores water at a constant 60.c to 90.c (adjustable)

and lastly. yes there's more
i also plan to build my own refrigeration system in the van to run a fridge freezer. it will purely be a 48v system. the compressor and condenser (radiator on the back of a fridge) will be under the van (for noise and the coldest place giving the maximum efficiency) also saving internal space. ill be using a pre-built fridge i think. though not very well insulated (to my standards anyway) it will just make things easy.
i also plan on having a microwave grill too. that will be ran from the UPS inverter. should just about manage.

hacked and slashed





now that's out the way, here is what i have done so far:
the evening i got it home i was sat in the van for a while reading through the booklets and various paperwork when i started hearing a buzzing/clicking sound. i traced the noise back to the rear left of the van, behind the lights. turns out the tow bar had an auto voltage detector for charging a caravans battery. this was looking pretty rough and quite melted to look at. i left it in place but pulled out the fuse. over the next 2 months i can report that the battery has never gone flat yet i have never really driven or even started the van up! will be an easy fix!

my first priority when i got the van home was to change the cam belt. 99k miles and a 15 year old cam belt is not odds that i like to play with. turns out its a really easy job on these vans. i locked the cam but never bothered locking the crank as i just used the visual timing mark to line it up. i replaced the water pump, tensioner and idler.i used a Gates timing belt kit. (we all know that they are the best!)







i also noticed that the throttle cable was very slack so "pegged" that back up a few notches. sadly this did not fix the engine power issue.
i also noticed that it had replacement discs and pads too!



now that was done i set about taking all of the original plywood out of the back. all in fantastic condition, all i planned to reuse again.
after cleaning the whole of the inside of the van with meths, my next priority was to install the extra 2 seats to the back. i wanted these seats totally removable as i still wanted to use it as a "lite van". my issue was that i wanted to have seats that could fold flat so i could lay a bed over the top of them. i also wanted them to have built in seat belts. all of which are quite rare things. i went into massive research looking for vehicles that have fold flat removable seats with built in seat belts. i eventually found out that Ford Transit Tourneo custom vans made after 2010 had just them! after contacting a few people i managed to buy two seats.
the seats fit perfectly in the original van floors "corrugation".
i welded in rather thick plate under the floor onto the chassis of the van so i had some very substantial seat mounting points. this did involve taking the fuel tank off in which i took advantage of the situation and repaired the very rusted fuel tank brace support, undersealed and rust proofed all chassis box sections using Dynax S50.
i bolted the seat runners in and installed the seats to test them before building the floor and its insulation.





i then set to insulating the back of the van. remember that 50mm XPS insulation i had left over? we that is what i used! this got used on the roof and the sides of the van. it fits perfectly depth wise.
i used expanding insulation foam (not the normal builders expanding foam) to hold the XPS in place. it also filled any missed cavities in the insulation due to my bad cutting skills.



for the floor i used 25mm square wooden batons and 25mm Celotex. then laid the original plywood flooring over the top of it all after cleaning and cutting out the holes for the now fitted rear seat mounting points.



i also insulated inside the steel cavities using polyester "teddy bear" stuffing as it does not hold moisture and remains breathable.



After all that was done i "sealed" everything in with thin plastic sheeting as a vapour barrier using aluminium tape to cover all of the holes into the cavities. (i also dynaxed some of the cavities, just for rust precaution)
i then covered all of the steelwork with 6mm closed cell foil lined foam. to give it a "warm/soft" touch then covered it all with Auto Carpet. no cold hard steelwork to touch in the middle of the night!





i did the same with the original plywood side panels after cleaning them and cutting them down to size to lay on top of the insulation vapour barrier.
i went for a dark grey auto carpet for all metal covering and a cream auto carpet to cover the plywood side panels. i will be using black auto carpet around the bottom of the "walls" of the living space. about 20cm from the floor up. i will disguise the colour change line using a thin strip of "ornate" aluminium checker plate.

i started work on a bulkhead with a plan to make a sizeable over head cupboard. before that i took out the old headlining, sound proofed and insulated the aerial with dense sound deadening sheeting and 10mm closed cell foam.







while i was under the van i had a poke around at the rust and made quite a "holy mess"... holy sh!t. well i can weld it all up but having done that much of it i am at the point where i just do not want to do that kind of thing anymore. i ordered new sills and planned to take it to a body shop to repair as they would make a much neat job of it than i would.





i planned to leave the roof with some plywood over it and then stain it a darker colour. however i am unsure with this idea and may change it.
from the photos you will notice that the van has a spinning roof vent. i have great plans for this. swapping out the vent for a low profile one so i can still fit my roof rack on. i plan to use it as an air intake system. now i suffer greatly with hay fever. so i will be building into the roof a HEPA air filtration system and aircraft style air vents. i am the kind of person that likes to sleep with the noise and feel of a fan blowing on me (i am really very highly strange). this in the summer months will be quite nice.
i have recently fitted a 2kw diesel air heater under the passenger seat. having cut out the "storage basket" to make way for it. i had to hammer flat some of the vans floor corrugation so it fit in nice and level. i did this using a trolley jack and a brick so i could hammer flat without concaving it. it fits in the gap really well but is close to fuel and brake lines under the van. i plan to make a heat shield for them. can never be too cautious. the heat output should blow nicely down the central walkway. between the seats and the kitchen units.












ok so as of today i have had the van for about 2 months and finally insured and taxed it. its insured as a camper in the conversion stage but still has SDPC specs so i can drive it to work
so far i have not looked into fixing the engine power issue. i took it out for my first drive in it and i was a little worried about it being as slow as it was. thankfully i know a thing or two about modernish diesel engines so i started to unplug sensors. well first sensor to unplug was the Mass Air Flow sensor (just behind the air filter box). low and behold it was like i hit LAUNCH on Saturn 5 rocket. that was easy. too easy. well i have ordered a replacement MAF sensor and a replacement inter cooler. i will fit them when they get here.

That is as far as i have got! on Friday i will be taking it into the body shop for the welding work to be done. the body shop specialises in repairing E7 Eurotaxis so no stranger to these vans. they also have many scrap taxis around the back. i may even buy all the bits to retrofit air conditioning to my van from them! just for the filtered air mainly!

thanks for looking! i will be sure to add more updates as it progresses.

just to note, i am keeping Vlogs on this hosted on Youtube.
see the playlist here:
https://www.youtube.com/playlist?lis...BnZSO2ISNI3vhn

-JohnDragonMan
Likes Didge3, jackwhoo, werdna, varesecrazy liked this post
Dragon Man is offline Reply With Quote Quote 
Old 04-06-2020   #2
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

sadly since i have been driving it i am 90% sure the clutch is on the way out. in 4 and 5th gear i can give it full acceleration and the engine revs but the speed does not change. the clutch feels fine when pulling off and going through the lower gears however. the place where i am taking it to get the work done specialises in repairing the taxi version of this van so i may ask them to do it for me. i also plan on buying of them all of the bits needed to retro fit air conditioning
Dragon Man is offline Reply With Quote Quote 
Old 04-06-2020   #3
Join Date: Apr 2011
Location: Near the M4
Posts: 25,158
Thanks: 952
Trader Rating: 0
varesecrazy has donated!
United Kingdom 
Quote Originally Posted by Dragon Man View Post
sadly since i have been driving it i am 90% sure the clutch is on the way out. in 4 and 5th gear i can give it full acceleration and the engine revs but the speed does not change. the clutch feels fine when pulling off and going through the lower gears however. the place where i am taking it to get the work done specialises in repairing the taxi version of this van so i may ask them to do it for me. i also plan on buying of them all of the bits needed to retro fit air conditioning

All that extra performance no doubt

Well worth getting sorted now.. is there a DMF on these..? I assume so..

Charlie
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

varesecrazy is offline Reply With Quote Quote 
Old 04-06-2020   #4
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

im just going to go for a clutch change. the previous keeper really rode the clutch but always had the engine revs high so that part should be fine.. thats if it has one! i need to do some research!
Likes varesecrazy liked this post
Dragon Man is offline Reply With Quote Quote 
Old 05-06-2020   #5
Join Date: Apr 2011
Location: Near the M4
Posts: 25,158
Thanks: 952
Trader Rating: 0
varesecrazy has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

My 99 jtd did have a DMF
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

varesecrazy is offline Reply With Quote Quote 
Old 05-06-2020   #6
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

1700 worth of welding. sigh this may be short lived. wish i had luck with cars
Dragon Man is offline Reply With Quote Quote 
Old 05-06-2020   #7
Join Date: Apr 2011
Location: Near the M4
Posts: 25,158
Thanks: 952
Trader Rating: 0
varesecrazy has donated!
United Kingdom 
Quote Originally Posted by Dragon Man View Post
1700 worth of welding. sigh this may be short lived. wish i had luck with cars
En estimate.. or a bill..??

Might be a mornings.. or a Sunday.. of your free time

As you said.. it wont be the prettiest.. but will be sound and affordable
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

varesecrazy is offline Reply With Quote Quote 
Old 13-06-2020   #8
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

ok so i told you guys about the welding quotes in excess of 1700. hot damn.

so i just started doing it all myself. so far i have one sill done. completely rebuilt with all serious rust chopped out and new steel cut to shape and welded in. no "cover it over with a patch" here. i did a video on it:

https://www.youtube.com/watch?v=5-ReRKiU7q4

be sure to skip to the end of my part 2 video on it here to see the end result as i never took pictures.. guhh

https://www.youtube.com/watch?v=h4KPExhqcjs&


i am now working on the back corner where the rear wheel sprays all the water and grit up.. have it all cleaned up, spot welds drilled, cut out and ready to make new steel parts and weld them in.
my plan is to make this a completely sealed cavity with just a little drain hole in it should water ever get in which it should not.

also i have bought almost everything needed to retrofit air conditioning into this van.
i made a topic >>Here<< (on another forum) for anyone foolish brave insane enough to follow me in the quest for perfection.

yes i have been up till now researching things on this van. its consuming me. finally something all the voices in my head can agree on.

... what?
Likes varesecrazy liked this post
Dragon Man is offline Reply With Quote Quote 
Old 13-06-2020   #9
Join Date: Apr 2017
Posts: 3,527
Thanks: 265
Trader Rating: 0
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Quote Originally Posted by Dragon Man View Post
ok so i told you guys about the welding quotes in excess of 1700. hot damn.

so i just started doing it all myself. so far i have one sill done. completely rebuilt with all serious rust chopped out and new steel cut to shape and welded in. no "cover it over with a patch" here. i did a video on it:

https://www.youtube.com/watch?v=5-ReRKiU7q4

be sure to skip to the end of my part 2 video on it here to see the end result as i never took pictures.. guhh

https://www.youtube.com/watch?v=h4KPExhqcjs&


i am now working on the back corner where the rear wheel sprays all the water and grit up.. have it all cleaned up, spot welds drilled, cut out and ready to make new steel parts and weld them in.
my plan is to make this a completely sealed cavity with just a little drain hole in it should water ever get in which it should not.

also i have bought almost everything needed to retrofit air conditioning into this van.
i made a topic >>Here<< (on another forum) for anyone foolish brave insane enough to follow me in the quest for perfection.

yes i have been up till now researching things on this van. its consuming me. finally something all the voices in my head can agree on.

... what?
You are doing a great job, huge well done.

I am so glad you have done the welding your self and so paid your self 1700 less cost of materials.

Thank you for the videos .

Cheers
Jack
Likes Dragon Man liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

jackwhoo is offline Reply With Quote Quote 
Old 17-06-2020   #10
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

oh we do love ourselves some pictures, dont we.

so i cut the outer skin off the sill, and i was greeted with this. what a pleasant sight indeed. time to get happy with the grinder



so that was fun time to start making new metal, yes some bits still looks rough but believe me, the magic of Dynax S50 will prevent future rust for many years.




anyway, cut a long story short and we have this result. silky smooth. not bad for saying i have no experience with using filler. i usually just grind my welds totally smooth. (my welds are just THAT flat to start with)



-----------------------------------------------------------------------------------------------------------------



oh OHHHHHHHHH What is this?! "Youve not!!" i hear you say, well yes. YES i have done the unthinkable. i have painstakingly undergone the tedious task (it was actually quite easy) of removing the air conditioning system from another vehicle (Peugeot E7 Eurocab).



some disassembly required... again not as bad as it looks.. by far the most easy vehicle to remove the dash from (excluding my old Fiat Panda 4x4, 5x "normal" screws )

really a T20 torques bit and a 10mm ratchet.. no problem this. 10 mins work!



now i "could" just attach this to my original air box system as it just happily sits on the back with 2 clips and a simple switch that turns the radiator cooling fan and compressor on (thats it!) but wheres the fun in that. you folks should know by now that its not the way I do things.
i need to get in with the wiring, become one with it (you will if you undo that loom!). i am just going to do the lazy thing and run new wiring alongside it. thankfully you get a nice wiring harness that just "plugs in" to your original vehicles wiring loom. that.. does seem... to be missing a few wires..... well im SURE it will be ok... i mean theres Already SO MANY.. i'm sure it wont mind a few not being there... ahem.
Moving right along..



now i do have to do some cutting out. remember i said that vans with aircon have 2 blower motors.. well turns out its a somewhat solid panel it mounts to. i was kinda hoping there was a plug i could just take out and to some extent there was.. but its too small. so Mr happy grinder time again.

this is how it should look...



and this is mine.




ahh but enough of that for now. check out this impressive filler work on the other sill the other side of the van. thats a good few mill thick that.




hmm nice.. wonder whats inside..


its like ive been here before! just everything is backwards now!

ahh and the bit i cut off? lets have a look and see the thickness of that filler work.. top job!



ahh but now it is time that i come to the end of my post..

till next time!
Likes Didge3, jackwhoo, varesecrazy liked this post
Dragon Man is offline Reply With Quote Quote 
Old 21-06-2020   #11
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

all of the rust has been cut out and new steel welded in.
the welding is complete.

before and after shot? you got it.




Likes varesecrazy, jackwhoo liked this post
Dragon Man is offline Reply With Quote Quote 
Old 21-06-2020   #12
Join Date: Apr 2011
Location: Near the M4
Posts: 25,158
Thanks: 952
Trader Rating: 0
varesecrazy has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Well on the way.. and saved you a fortune

Top job
Likes Dragon Man, andydiver liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

varesecrazy is offline Reply With Quote Quote 
Old 21-06-2020   #13
Join Date: Apr 2017
Posts: 3,527
Thanks: 265
Trader Rating: 0
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Pay yourself 1800 because you did the sections behind wheels too
Grand job
Thanks for updates and pics
Jack
Likes Dragon Man liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

jackwhoo is offline Reply With Quote Quote 
Old 22-06-2020   #14
I Void Warranties
 
Dragon Man's Avatar
Join Date: May 2011
Location: The East Midlands, Derby.
Posts: 5,094
Thanks: 299
Trader Rating: 0
Dragon Man has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

clutch change time!
yes thats me!



so had to drain the gearbox oil, surprisingly clean looking! magnetic drain plug also is rather clean for 100k miles. wonder if its been changed before?





while taking the bumper off i found this.. well worth addressing as i bet everyones is like this!


and ill also be cleaning up, up here too!




still tempted to take off the sub frame completely so i can clean it up and repaint it. from what i have seen it is pretty rust free, just the bit s where its starting to get under the paint and rust out. wire wheel time! ill also fill it with dynax when i am done. protect the inside of it.

thats all for now!
Likes varesecrazy liked this post
Dragon Man is offline Reply With Quote Quote 
Old 22-06-2020   #15
Join Date: Mar 2014
Location: Thetford
Posts: 592
Thanks: 48
Trader Rating: 0
andydiver has donated!
United Kingdom 
Re: JohnDragonMan's Dispatch/Scudo Micro Camper Conversion

Your contributions are brilliant. Thank you.
Likes Dragon Man liked this post
__________________
FIAT Forum Useful Links:
Donate to FF | Buy FF Merchandise | Classifieds | FF Insurance | How-to Guides

andydiver is offline Reply With Quote Quote 
Reply
Currently Active Users Viewing This Thread: 1 (0 members and 1 guests)
 
Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off

Forum Jump
Similar Threads
Thread Thread Starter Forum Replies Last Post
Ducato Camper conversion Samp21 Newbie Central 4 19-05-2015 08:59
Doblo Camper conversion Woolpack Newbie Central 5 09-01-2015 13:54
(G) scudo/dispatch 55 plate heater controls light bulb replacement abarthmark Scudo 0 01-01-2007 17:55