Ex-BG Caddy Maxi Camper Build

[charlie-]

Just got myself an Ex British Gas Caddy Maxi that I’m planning to convert into a mini camper. Going to hopefully keep track of my progress in this thread!



I’m still not settled on the exact layout/style I want in the back but do really like this conversion I found when I was searching for inspiration. I know I definitely want a sofa/bed, sink and gas hob unit and a small fridge.



I’ve got a pretty long wish list for mods and changes so far. Every time I view a build thread on here I want to add more I’m not sure if I’ll actually get to all of these, depends on finances and time. The camper conversion stuff is the priority for now though rather than stuff like colour matched bumpers, but will probs get to some other stuff that’s cheap/quick to mod.

To-Do

Completely strip out the rear cargo area, remove unwanted BG wiring and bulkhead
Remove seats and deep clean entire interior
Full wash, clay, polish, etc. exterior and wheels
Reversing camera (I think my existing head unit supports this, not 100% though)
Rear internal barn door handle
Glovebox cover
Apple CarPlay head unit (not sure which, prefer the OEM look really)
New ply lining for interior side panels and floor
Install slide open windows on one or both sliding doors (one might just be a fixed window, not sure yet)
Soundproof, insulate and vapour barrier
Leisure battery and inverter with electrics for lighting, tap water pump, small fridge, power socket
Carpet and wooden slats ceiling
Build bed frame and side unit
Install sink/hob
Small fridge
Auto headlights
Fog lights
Roof bars
Colour code bumpers and possibly mirrors
Install colour coded door rail covers
Cruise control
Heated seats
New wheels
Lowered a little, not a fan of the completely slammed look and want the van to be practical. Don’t want to worry about speed bumps too much.

[the swan fiend]

Hi mate, welcome to the forum. Looks like a tidy example van you’ve got there. Sounds like you’ve also given yourself some work to do too!
I did see a converted ex BG camper on auto trader a while back,. It had been professionally done by the looks of it and was up for £22k


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[C Chis]

Welcome buddy!

You've got yourself a great base to build your micro camper on!

Good to see you've pulled an impressive list of mods together, it will grow!

[charlie-]

Not had much chance to update this but made some good progress with the van over the last couple of weekends.

First up was to completely strip out the van, remove all the racking and extra wiring that British Gas add to the van. Then remove the bulkhead and give everything deep clean.

I ended up having to remove fair amount of the trim to get at some wiring and at that point figured I might as well go all in and take the headlining, centre console and rear footwell carpet out

First up awful seat covers off and in the bin and seats out for a clean.





Some steam cleaning action later seats came up a treat. Forgot to take a before pic, but they were a mess. Covered in dirt and few stains.



[

Next up racking out, bulkhead out and all the cargo area trim out.











Rear carpet out.



Headlining out.



And steam cleaned.



Out with the BG wiring.



Found the original locking petrol cap under the passenger seat carpet. Out with the awful yellow one!







A lot of hoovering, steam cleaning trim and wiping everything down later.

[the swan fiend]

Looks new that mate. Properly clean!


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[Ripley55]

Jeepers mate, you’ve knocked your nuts in on that looks straight from factory

[charlie-]

Cheers, got a bit carried away with the cleaning

Van-x glovebox fitted.



USB port/button fitted.



Rear window blackout vinyl removed.





Bulkhead cut down and tidied up.





Full service completed and replaced the pollen filter. Not surprisingly it was still the original factory fitted one from 2013! Garages always seem to skimp on replacing these in services. Helps freshen up the air system no end though.



New one with active carbon and anti microbial coating installed.

[charlie-]

Camper Glass tinted sliding privacy windows arrived last weekend. I was definitely a bit nervous about installing these as it means cutting some pretty large holes in the van

Turned out ok though! Installed and no leaks. Used a hole saw initially for a starting point then an air nibbler to cut the section out. If I ever do this again I’ll do a better job of taping up plastic sheeting around the cut area, took forever to clean up the mess!



Knock on trim installed.



Windows in.





Van Demons roof rails arrived. Decided to go with these rather than random eBay ones as TUV approved and only slightly more money.

[charlie-]

Next job was installing sound deadening and cutting the ply floor. I ordered a bulk pack of 2mm Silent Coat (40 sheets) and volume pack of 4mm (12 sheets). Used the 4mm on the arches, 2mm everywhere else. The wheel arches are the only place with full coverage.

It’s made a noticeable difference already to the road noise.







Managed to do the entire floor with a single sheet of 9mm 2440 x 1220mm ply in two sections. Took a while but means I’ve avoided needing small offcuts for the sections around the arches. I’m planning to use the tie down points to secure the ply once I’ve got the rest of the insulation in. I’ve got a 10m x 1m roll of Dodo Thermo Van Liner for the main insulation/vapour barrier.



I need to sort out the leisure electrics for the camper stuff which is holding up installing the rest of the insulation and then carpeting.

[charlie-]

Tidied up a few rust spots in the cargo area where water had pooled in the tie down points and the trim by the barn door striker plates. I wanted to sort this before covering the area with the thermo liner.

Rust sanded down, treated with bilt hamber rust converter and then primer.



Hit my first snag with the striker plates...



Out with the drill and screw extractor set.





After much hammering and swearing.





All sanded down.



Rust treated and primed.



No need for body coat as the area will be entirely covered by insulation, trim and carpet.

Decided to tidy up the striker plates and fasteners with the sand blaster at work.









Missing door card reflector arrived from China so popped that in.

[the swan fiend]

You’re flying with this mate! Top work


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[Danieljthomas]

Hi, new on here. About to start my own conversion of a caddy maxi. Loads of great tips here, thanks for running through everything .

[tomo88]

Nice work dude

[Ripley55]

@charlie-
Some great work there. I see you put the headlining back in, any plans to colour that and the A Pillar trims ?

[charlie-]

Cheers guys, slowly getting there!

@Ripley55 I might give it a go once the camper stuff is done, have you done it on yours?