rb panel van conversion begins !

[Kool Kroozer]

Aww Ralph, giving us little titbits ere n there - ya such a tease As per usual though - looking good as always - clever git

 

[Ralph-n-Bev]

We both had rubbish sleeps last night. Pug had to go to the Peugeot garage for a recall on a part in the engine. Plus they are doing a free health check.
Ralph took him over , handed over the keys and left Him in the customer car park.
Once home he realised that he'd not shut the blinds. This was about 7 pm. So he went back again with the spare key.
No staff around , but quite a few people browsing cars , even though the place was shut.
So he just opened the van. Setting the alarm off in the process......not having a key alarm, just the spare. To turn it off........
Closed all the blinds, locked up and left .

Can you imagine if someone pinched Pug now??
Obviously we are fully insured , but even so.
There are barriers , which were closed. But it was a stressful sleepless night. Like leaving a baby for the first time
I haven't had a call , saying Pugs been stolen ..... So all must be well.

 

[Kool Kroozer]

All must be ok Bev

 

[JockandRita]

Ralph & Bev, we are just back from our hols across the water, and now catching up with posts.

As expected, the work on the tanks looks great. I wouldn't have been happy without the tank insulation either, despite the assurance of the produsct being good to minus 6°c. We can experience an ambient temperature of minus 15°c here during a hard UK winter. Add to that the chill factor when motoring along, and the insulation becomes essential.

Great photos of the progress so far.

Cheers,

Jock.

 

[Bongo]

Wow, what a magnificent build. Thank you so much for sharing.

Hats off to you for going out and building what you wanted on the vehicle of your choice.

Top quality components and materials used across the board too. Fantastic!

Wishing you both many years and miles of adventure in your furture classic pug!

^{_{Subscribers  do not see these advertisements}}

 

[mitzimad]

Ralph & Bev, we are just back from our hols across the water, and now catching up with posts.

As expected, the work on the tanks looks great. I wouldn't have been happy without the tank insulation either, despite the assurance of the produsct being good to minus 6°c. We can experience an ambient temperature of minus 15°c here during a hard UK winter. Add to that the chill factor when motoring along, and the insulation becomes essential.

Great photos of the progress so far.

Cheers,

Jock.

the chilll factor has no bearing on weather tanks freeze, it only effects people if it was one degree with a wind chill of minus ten the water will not freeze
we feel it as we produce heat and the wind takes it away hence the chill

 

[JockandRita]

the chilll factor has no bearing on weather tanks freeze, it only effects people if it was one degree with a wind chill of minus ten the water will not freeze
we feel it as we produce heat and the wind takes it away hence the chill

But surely, if you add a speed of 50-60mph into the equation, doesn't that alter things dramatically. As an example, if you spray water onto a cold dry windscreen whist stationary, it may take time to freeze, but if you do the same at speed, it will freeze immediately, hence the need for screen wash additive, so if an untreated water tank's contents is exposed to the same extreme temperatures, and at speed, surely it will eventually freeze?

Just my layman's view on the matter, and nothing more.

Cheers,

Jock.

 

[Terry]

Hi Jock the water is in a tank so does not get affected by wind chill -if it did your washer tank would freeze and you would get no water-water in a moving vehicle will move around and help stop it freezing
terry

 

[JockandRita]

Hi Jock the water is in a tank so does not get affected by wind chill -if it did your washer tank would freeze and you would get no water-water in a moving vehicle will move around and help stop it freezing
terry

Terry,
I have operated trucks, where in the yard on a freezing 03.00 start, the screen washers have worked fine, but a few of hours driving at motorway speeds, (wind chill) and on inspection, the contents has started to freeze, because an additive hadn't been added. Albeit a smaller quantity amount of water I grant you, but an unprotected plastic translucent tank, without heaters or insulation nonetheless.

Why is it that the external mounted grey waste tank on our 99 Hymer, is not only fully encased, (as is the ball valve mechanism) but it is totally insulated, including the removable cap to the inspection hatch? Just saying like.

Cheers,

Jock.

 

[Terry]

Hi Jock wind cannot blow through a plastic/metal tank -only onto it
terry

^{_{Subscribers  do not see these advertisements}}

 

[Techno]

I was all ready to agree with your logic Jock but I had to google first

1. 
   The only effect wind chill has on inanimate objects, such as car radiators and water pipes, is to more quickly cool the object to cool to the current air temperature. Object will NOT cool below the actual air temperature.

 

[JockandRita]

Hi Jock wind cannot blow through a plastic/metal tank -only onto it
terry

And if you blast that unprotected tank with sufficiently freezing cold air for a long enough period of time, the contents (if untreated water) will eventually begin to freeze, even quicker if the tank was made from metal or glass
I never could understand why so many British built MHs have exposed underslung tanks.

I'm off out shortly Terry.

Cheers for now,

Jock.

 

[JockandRita]

I was all ready to agree with your logic Jock but I had to google first

1. 
   The only effect wind chill has on inanimate objects, such as car radiators and water pipes, is to more quickly cool the object to cool to the current air temperature. Object will NOT cool below the actual air temperature.

At least I wasn't on my own........................at one stage Andy.

Cheers,

Jock.

 

[Ralph-n-Bev]

....Listen at you lot.

Can't comment yet on wind chill but we did a weekend in Hawes not long back and it got to -6

This was a good test for the Pug at -6.
Nothing froze up Didn't need to use the freshwater tank element either

The cold weather also gave the new Webasto Evo 40 a good running in

With good insulation all round the van was toasty warm with the heating just ticking over.
The new Evo 40 has a quieter running fuel pump than the old 3900. After the initial heat up you dont get the ticking sound from the pump.
All in all a great heating system, very very quiet and economical in use.

Anyway....Thanks for resurrecting the old Pug thread. Its given me a kick up the backside to finish the build thread.
As promised i will work out and post the total costings and overall thoughts on the self build route.

Cheers.....Ralph

 

[haganap]

have to say the moment you said you were doing it Ralph, I knew it would be a work of art and it sure is.
well done, bout time the building lark was knocked on the head for the new R&B conversions.

^{_{Subscribers  do not see these advertisements}}

 

[JockandRita]

....Listen at you lot.

Yep, and after all that lot, I'm still not convinced Ralph. Temperature transfer springs to mind.

Anyway....Thanks for resurrecting the old Pug thread. Its given me a kick up the backside to finish the build thread.

If @mitzimad (Dave) had been bang on the mark back in late September, (instead of waiting for @Bongo's post this morning) the thread would have been resurrected much sooner.

As promised i will work out and post the total costings and overall thoughts on the self build route.

Looking forward to that Ralph, and I hope the whole project hasn't put you off doing another one, ie, as a business venture perhaps.

Cheers,

Jock.

 

[Ralph-n-Bev]

So.....Back in January 2015 we took delivery of a new Peugeot Boxer with the intention of converting it into a Camper van.

Broken Link Removed
After around 900 working hours it looks like this......

Are we Happy ?? Yes of course we are

After the joiner who was doing all my woodwork let me down i was devastated. I was left with no choice but to give it a go
I am so glad i did as i have totally surprised myself with this conversion.Doing it myself gave me a chance to tweak and change things as and when required. If i ever need to undo anything i know how it was put together and where all the fixings are.

No regrets on the downsize from a 7 berth coach-built to a Panel van. Driving now is so easy. The windy country roads are just a pleasure to drive on, you dont get the top heavy swaying on the bends like we did with the CI.
Fuel economy is better. Having a narrow van is also a plus, parking in normal spaces is achievable.
The biggest plus for me is that Bev will now drive meaning i can have a beer

We took the pug up to the Western Isles and touring around was just so easy in a smaller van.It just feels like it was made for places like this.
We felt confident taking narrow single track roads down to lovely secluded white beaches.

The rear lounge layout really works well for us. we feel you have the best of both because its so easy just to roll out a couple of Duvalays and thats it...beds made, Pack them away you have a spacious rear lounge with near all round views. Storage was a bit of a concern downsizing but we have more under sink cupboard storage in this van. The rear lounge seat bases have plenty of storage because the heating and hot water systems are outside under the van.We also have four lockers each which seem to be more than enough for a weekend away. Another very handy space on a panel van is the over cab storage.Up there we keep coats, umbrellas and the cab silver screen. Last but not least we have a wardrobe for two above the fridge.

The kitchen area again just seems to have more working space than the CI.The addition of flip up work surface makes all the difference.
Very pleased with the Spinflo Triplex oven and matching sink. Highly recommend the oven to anyone looking to buy a new oven. We went for the 3 ring burner and it works very well.

The wet room is the only area where we feel that we have downsized . We had the luxury of a bathroom right across the back of the CI with one side having a separate shower cubicle. Given the size of the van we are more than happy with what we have and you can still shower.
I actually like the space saving drop down sink and the bench toilet is very comfortable i might say

We have been catching up on lost time recently and taking any chances to get off in Pug. So far we are very pleased with our choice it just suits our type of Motorhoming....a night here a night there, moving on is so easy in a van like this.It is built how we want it with everything we need and nothing we dont. Selfbuild gives you a chance to build the perfect van to suit you. All those extras and boys toys we all add on later can be built in as you go along

Selfbuild has been a big learning curve for me, you really have to think ahead and have a plan even if its in your head.
Its not been easy and takes over your life at times but the rewards are massive. Every time i go in the van i cant believe i built it

WOULD I DO IT AGAIN ? ......No, not while working full time anyway, it almost killed me and affected my drinking

WOULD I DO IT AGAIN WHEN NOT WORKING FULL TIME ?.....Yes with all the time in the world i would love to, its very rewarding work

So how much have we spent ? I will put the costings together on my next post.

Big thanks to all the funsters who have followed and helped me through this....its been FUN

Cheers.....Ralph

 

[JockandRita]

A great read Ralph.

I am really glad that you have no regrets.................other than it affecting your drinking.

The finished vehicle is an absolute credit to you. I would have chosen more than one "like" to your post above, but the system won't allow it.

Happy MH'ing to you and Bev, in your new passion wagon.

Jock.

 

[Ralph-n-Bev]

Cheers Jock

Hope we catch up this year. Are you down for Misterton ?

 

[JockandRita]

Are you down for Misterton ?

Sorry, but no Ralph. We are going straight from Stratford down to the Bagwell Farm Meet.

I see that you are down for York, so we'll see you and Bev there.

Cheers for now,

Jock.

^{_{Subscribers  do not see these advertisements}}

 

[Peter & Elaine]

Just for anyone who has not actually seen the pug and I am pleased to say I have
Non of those photos do it justice
If a master carpenter built it he would be proud
For a bricky in his back yard it's a bloody work of art
It's by far the best one I have seen and that includes the pros at £60k plus


(Even though I still think Bev did it )

 

[Peter & Elaine]

I

Sorry, but no Ralph. We are going straight from Stratford down to the Bagwell Farm Meet.

I see that you are down for York, so we'll see you and Bev there.

Cheers for now,

Jock.

I have still got a red bucket with your name on it

 

[JockandRita]

I

I have still got a red bucket with your name on it

Top man Peter.

Cheers,

Jock.

 

[Ralph-n-Bev]

Just for anyone who has not actually seen the pug and I am pleased to say I have
Non of those photos do it justice
If a master carpenter built it he would be proud
For a bricky in his back yard it's a bloody work of art
It's by far the best one I have seen and that includes the pros at £60k plus


(Even though I still think Bev did it )

Cheers Peter, A bricky in his back yard....really sums it up...Cant argue with that

BTW, You got that B to B wired up yet ?

 

[Ralph-n-Bev]

So as requested here is a breakdown of the build costs for the Pug Panel Van Conversion.

Our intention was to use the best available materials and parts throughout. We also wanted a conversion that would last us along time
I could have done it a lot cheaper and suppose i could have spent more in some areas.Overall we got the quality and look we were after.

I will try and break it down so you can see whats been spent on each area of the build.

Base Vehicle

So you know the conversion was on a new Peugeot Boxer 2.2 Extra long wheel base.
We specked up the van adding some extras. So glad we did, never had some of them before but wouldn't be without them now.
Here is a list.....

Cruise Control / Speed Limiter
Reversing Camera linked to central radio system screen
Satellite Navigation
Bluetooth Radio
Cab Air Con
Uprated Alternator 180A
Reinforced Battery
Engine under-Tray Protection
Front and Rear Mudflaps
Uprated Tyre's 16" Four Season
Alloys
LED day running lights
Rear Suspension Upgrade
Metallic Paint

Base vehicle with extras and Vat £ 21,788.00

Electrical

Lights,Leisure batter,Charger, Inverter, Wiring, Wiring components,CBE Sockets, 240v Circuit Breaker,Ducting,Connector blocks,Relays....Etc

£ 3,116.00

Water & Plumbing

Water Pump, Piping, Pipe Connectors,Taps, Shower Tray, Shower, Toilet, Fresh and waste water tanks, Kitchen Sink...Etc

£ 1,409.00

Interior Building Components

Furniture boards, Insulation, Flooring Sheets, Wall panels, Ceiling Boards, Wall finishes (Veltrim) Adhesives, Sealants, Bathroom wall Panels
Spray foam, Spray Adhesive, Screws & Fixings....Etc

£ 3,282.00

Gas Components

Underslung Gas Tank & Brackets, Regulator, Gas fitter Fees, Gas fittings, Gas Taps, Flexi oven Connector, Copper Pipe...Etc

£ 656.00

Webasto Heater System

Heater unit with all ducting and vents

£ 1,656.00

Windows & Rooflights

Seitz Windows x 5, Roof Vent Fan, Bathroom Roof Vent, Lounge Roof Vent.

£ 2,204.00

Other Items

Fridge £821.00
Nasa BM2 Battery Monitor £ 110.00
Sog £ 150.00
Vinyl Flooring £ 89.00
Remis Cab Blinds £ 532.00
Regal Furnishings, Interior Foam and Upholstery £ 1,750.00
Fiamma Roll out Canopy £ 669.00
Electric Step £ 300.00
180W Victron Solar System £ 488.00
External Water Heater £ 580.00
Seat Swivels £120.00
Cooker £443.00
Rear Bluetooth Radio And Speakers £ 236.00

Grand Total £39,720.00

Happy with That

We never really had a fixed budget on this project but i originally estimated the conversion costs to be around the 15k mark
As it stands its cost £ 17,932 but not disappointed at all, As i said before we have everything we need and nothing we dont....Perfect

I hope this breakdown helps anybody considering doing their own build.If you were on a budget you could knock a lot off what i have listed.
The Electrical system on this van is all Victron gear, it doesn't come cheap but it works very well and will last. Some of the list of other items above is like a list of extras you would add to a new Motorhome....You dont have to put them on. The base vehicle doesn't have to be new or have all the bits i have put on to make a great camper van.

What i have learned from doing my own conversion is the amount of work that goes into building a Campervan....Around 900 Hours it took me
Admittedly if i did another using all my templates I would save hours and hours.
Buying every part of a Campervan bit by bit is a big eye opener you wont believe all the relays and electrical connections there are tucked away. The price of some parts just blew me away....HOW MUCH FOR A 12V FRIDGE

You really can see where manufacturers get their prices from. Put a labour price on my (approx 900 Hrs) hours and it really ads up.

So there it is The making of our Pug

Hope you have enjoyed this thread... I certainly enjoyed everyone's encouragement along the way...Thank you all

Ralph & Bev

^{_{Subscribers  do not see these advertisements}}

 

[Paddywack]

Brilliant write up as I would expect!

Don't forget the volume manufacturers will be buying things at trade prices and recovering the vat which would probably bring your components costs down considerably.

 

[Ralph-n-Bev]

Thanks a lot.
Yes your right. Plus I've cut each piece of wood by hand . They will have patterns and machines to do 100+ at a time, plus we chose top quality Board . That would bring it down considerably too.

 

[Landyguy]

Fantastic read and well done and making your dream machine - have to try and persuade the Mrs we could fit in a PVC rather than coachbuilt but doubt I will get away with it. Would love to make one like yourself but doubt it would be as good - you should be very proud of what you have achieved.
CONGRATS

 

[Anthea M]

So.....Back in January 2015 we took delivery of a new Peugeot Boxer with the intention of converting it into a Camper van.

View attachment 91562 View attachment 91563 Broken Link Removed
After around 900 working hours it looks like this......

View attachment 91565 View attachment 91567 View attachment 91571
View attachment 91566
View attachment 91572 View attachment 91573 View attachment 91574

Are we Happy ?? Yes of course we are

After the joiner who was doing all my woodwork let me down i was devastated. I was left with no choice but to give it a go
I am so glad i did as i have totally surprised myself with this conversion.Doing it myself gave me a chance to tweak and change things as and when required. If i ever need to undo anything i know how it was put together and where all the fixings are.

No regrets on the downsize from a 7 berth coach-built to a Panel van. Driving now is so easy. The windy country roads are just a pleasure to drive on, you dont get the top heavy swaying on the bends like we did with the CI.
Fuel economy is better. Having a narrow van is also a plus, parking in normal spaces is achievable.
The biggest plus for me is that Bev will now drive meaning i can have a beer

We took the pug up to the Western Isles and touring around was just so easy in a smaller van.It just feels like it was made for places like this.
We felt confident taking narrow single track roads down to lovely secluded white beaches.

The rear lounge layout really works well for us. we feel you have the best of both because its so easy just to roll out a couple of Duvalays and thats it...beds made, Pack them away you have a spacious rear lounge with near all round views. Storage was a bit of a concern downsizing but we have more under sink cupboard storage in this van. The rear lounge seat bases have plenty of storage because the heating and hot water systems are outside under the van.We also have four lockers each which seem to be more than enough for a weekend away. Another very handy space on a panel van is the over cab storage.Up there we keep coats, umbrellas and the cab silver screen. Last but not least we have a wardrobe for two above the fridge.

The kitchen area again just seems to have more working space than the CI.The addition of flip up work surface makes all the difference.
Very pleased with the Spinflo Triplex oven and matching sink. Highly recommend the oven to anyone looking to buy a new oven. We went for the 3 ring burner and it works very well.

The wet room is the only area where we feel that we have downsized . We had the luxury of a bathroom right across the back of the CI with one side having a separate shower cubicle. Given the size of the van we are more than happy with what we have and you can still shower.
I actually like the space saving drop down sink and the bench toilet is very comfortable i might say

We have been catching up on lost time recently and taking any chances to get off in Pug. So far we are very pleased with our choice it just suits our type of Motorhoming....a night here a night there, moving on is so easy in a van like this.It is built how we want it with everything we need and nothing we dont. Selfbuild gives you a chance to build the perfect van to suit you. All those extras and boys toys we all add on later can be built in as you go along

Selfbuild has been a big learning curve for me, you really have to think ahead and have a plan even if its in your head.
Its not been easy and takes over your life at times but the rewards are massive. Every time i go in the van i cant believe i built it

WOULD I DO IT AGAIN ? ......No, not while working full time anyway, it almost killed me and affected my drinking

WOULD I DO IT AGAIN WHEN NOT WORKING FULL TIME ?.....Yes with all the time in the world i would love to, its very rewarding work

So how much have we spent ? I will put the costings together on my next post.

Big thanks to all the funsters who have followed and helped me through this....its been FUN

Cheers.....Ralph

Fantastic!!!

 

[Manic]

Brilliant, a credit to you

^{_{Subscribers  do not see these advertisements}}