Jon’s camper/MTB conversion

[Jonhall]

Hi all, only my second post but thought I’d share some of the progress so far on my camper build!

Collected the van three weeks ago and have spent many evenings on the driveway getting the project underway.

My Caddy is a 2017 Maxi Highline 2.0TDi 150 DSG with tailgate and was in superb condition, so the initial strip out and prep was less onerous than first expected.

So far, we’ve ticked off:
- new starter battery (original one had a dead/dying cell)
- Split charging system with Sterling BBS1230 DC-DC charger/solar regulator
- 130AH AGM leisure battery and 12v distribution panel
- false floor and service panel behind passenger seat to conceal the electrical systems
- LED spotlights in ceiling
- LED reading lights
- Fast charge USB sockets
- Dodo sound deadening
- Dodo Thermoliner and Thermofleece
- door panels made from 3.6mm ply using factory originals as template
- one piece headliner made from 3.6mm ply
- bulkhead sides repurposed as trim for B pillars

Next steps will be to cut out and fit bonded windows (when I get my hands on a compressor and nibbler) and Planar 2D heater behind driver’s seat.

I’ll update as we go along! Any feedback/advice welcome

Stay positive and test negative!

Jon












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[Wenny95]

Looks like you have had your work cutout for you the past few weeks haha. Looking great though. Keep us updated would love to see the finished build.

[Jonhall]

Insulation now complete and floor panel made/fitted. Just waiting for some longer bolts to secure the floor panel to the threads from the tie down points.





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[Jonhall]

It’s been slow progress over the last few weeks!

Managed to get an offcut of vinyl from a local flooring shop to use as a temporary floor covering. When we get the furniture sorted, we plan to use some Altro vinyl as the final solution.

Fitted a Vanstyle bumper protector as well, although it’s hard to see against the body-coloured black bumper in the wet.




Went for a walk and first brew with a view in the Caddy



Also got a delivery from Blok Products to complete the mountain bike setup. I’ve ordered some Hope wheel bags (the only ones I found that take a 29” wheel with tyre) to keep the van clean(ish)




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[sendgineer]

Awesome work so far, look forward to see how you get on with this

[Jonhall]

Engine cover fitted - I searched high and low for a VW one at a sensible price but had to settle for an Audi one in the end. Might add some Quattro badging?




Also installed some Dodo bonnet liner, figured it would be worth a go for £20.



And had a delivery from Camperglass! Two fixed windows for the sliding doors and a single pane for the tailgate. I’m planning to get these fitted over the next couple of weeks.



Final bit of progress for now was booking in with Rising Sun Campers to have the diesel heater fitted later this month.


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[Toonez]

How do you get on with the blok mounts. Can you easily get multiple bike in without handle bars touching?

[Jonhall]

[mention]Toonez [/mention]the offset plates mean you can get the bikes close enough that the rear axles/mechs coming together is you need to watch out for!

https://www.blokpod.co.uk/product/off-s ... unt-rails/

In my earlier photo, I’ve got both plates ‘straight’, with one all the way forward and the other all the way back. Plenty of room for my 27.5” full sus and my friend’s 29” hardtail.

Depending on what bikes you’ve got, I reckon you could get 4 MTBs in by getting creative with the angle/position of the offset plates.

Hope that helps!


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[Jonhall]

Made a slight modification to the split charging system tonight. The Sterling DC-DC charger kicks in when the ignition is switched on, using a feed from the ignition live rail on the fuse board as signal.

I decided to add a switch onto this ignition feed so that I can have the ignition on without the leisure battery being charged. Should be useful for periods between camping trips when the leisure battery doesn’t need topping up etc.

The green sharpie mark was my planned switch location but couldn’t get the drill in there!




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[Jonhall]

Managed to make a start on carpet lining the panels over the last few days. I’ve used 3.6mm ply and ‘invisible’ trim clips (the twist in/fir tree type). The carpet is from Combe Valley Campers

Will be attempting windows tomorrow!










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[Jonhall]

Update on window fitting: managed to get both sliding doors done today (with the benefit of an extra pair of hands)!

Really pleased with how it went and the fitting kit from Camper Glass was just the job. The air nibbler made light work of the cutting and left a super clean edge to work with.

I also took the opportunity to install the awning rail in the passenger side gutter. Had to get creative with a ratchet strap to hold it down along the curve of the cab roof (did the job though).

Tailgate window is next on the list


















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[Jonhall]

Tailgate window installed this week, along with new gas struts. The additional weight of the glass exposed how tired the originals were, but much better now!

















Also spent a chilly evening insulating the roof over the cab. I’ll probably come back to do the front doors and footwells once we’re up and running in camper form.



Managed to rope in some help (supervision) to get a couple more panels carpeted, along with the sides of the bulkhead we saved to trim the B pillars.






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[Marcmcq90]

Loving that mate!

I’ve got a SWB life and therefore the tailgate and glass… yours looks so much better without the wiper on the back window!

Looking forward to seeing more progress

[Jonhall]

Cheers [mention]Marcmcq90 [/mention]

I’m really pleased with the stealthy look but a wiper wouldn’t go amiss at the moment


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[Jonhall]

A bit more progress since my last update…

I’ve finished installing the curtains thanks to judicious use of a rivet gun (much neater finish in my humble opinion). Both sliding doors and tailgate window with the kit from Van-X.






We also made a trip to see the good folks at Rising Sun Campers on Friday to have a diesel heater fitted. It’s a Planar 2D with comfort controller and fuel feed from the main tank. I’ve tried it already while working in the van and it certainly works!







Finally, I managed to give it a proper wash to get rid of the winter muck (for now…)





That’s all for now, off for a few days to the West Wales coast (Airbnb but travelling Caddy class )


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