K9 CAMPER VAN PROJECT

BEFORE
 

AFTER

Above-pictured in Holland with Chuba and Chila-Sept 2004

Above-at Calais Channel terminal-Sept 04

Part One-The Search

Because many people who show their dogs, also tow caravans and camper vans around the show circuit in summer, I thought my experiences may be of interest to the readers. Ok, so I must admit that possibly I have reached a mid-life crisis; something just ain't right, I started dog showing about 3 years ago and to the horror of my mid-twenties offspring, (guess who borrowed it for a weekend away this summer?) have been talking about getting a camper van (or motor home in posh circles). What Dad, a camper van? You are joking? That is what retired couples drive around the country lanes at 29 MPH whilst admiring the scenery, is it not? No, son, this is gonna be a flying machine, one that I can just jump into with a couple of dogs onboard, and go off to the dog shows at the turn of the ignition key. Having always been used to trailing a caravan around in the UK and abroad, I have finally decided that a motor home type vehicle for odd one or two night stays, would be much more practical than my mini-articulated rig, especially with the dogs in mind. My better half Janet has also now agreed that this would be more convenient for our type of touring requirements.

So, the quest to find my perfect vehicle began. It had to be a diesel (preferably turbo-charged), and had to be large enough not to be cramped with up to two or three people and three dogs aboard, whilst nimble enough to be sensible for reasonable car park access. When towing the 'home on wheels' one often has to by-pass those quaint little public houses which serve up good reasonably priced food as opposed to what is on offer at our motorway service stations. Looking through the classified ads in the various motor home magazines, it seemed that one had just four choices; "A" class motor homes, including the mobile mansions from the US (far too large and expensive); the coach-built type vehicles like Swift Kontiki etc. These were also much too expensive, and not really the perfect layout to keep large dogs aboard. Also, I often wonder if that large white blob over the cab (bunk bed) can really remain stable on a windy motorway with only a 2.5 litre engine to power the whole unit. Thirdly, so called 'camper vans', the majority of which would be seriously claustrophobic with anything larger than a Yorkshire Terrier as company. So that just left the fourth option, buy the biggest commercial van you can find, and give it a touch of the DIY conversion special. Plenty of time and thought should produce a half-decent looking job, I reckoned. I was determined to avoid the temptation to buy one of those ex-mobility, mini-bus type vehicles, available quite cheap, but always reminiscent of the New Age Travellers on their way to a pop festival, no matter how hard you try to convert it.

Finally, an advert in the local Auto Trader led me down to a chicken/turkey farm in South Yorkshire. There it stood, a high mileage but one owner Mercedes 811D van, still in original condition. Having only ever been used for delivering trays of eggs around Barnsley and Sheffield, it had led quite an easy seven-year life with no evident abuse. Having had a short test drive, the deal was done, and home it came. The dogs gave it more than just a quick once over, the smell of manure on the chassis and rotten old eggs in the back was a delight to a TM nose. A good blast with the power washer was called for.
 

Part 2-Design and Build..."Hack up"

The very first job was to cut out the bulkhead, the metal partition dividing the cab from the cargo area. The filthy liner was ripped out, exposing the bare metal, and out came the angle grinder...noisy, messy and a bit of a butchers job really, but eventually the bulkhead partition was out, and the bare metal was liberally painted with red oxide. 'It looks much bigger already', I thought, as I looked back from the drivers seat enjoying a well deserved cuppa and a smoke. Then out came tape measure and A4 sheet, time to put some of my mental designs down on paper. 

After many sketches and chalk marks on the floor, I finally decided on how the layout was to going to be. This part is crucial, because everything which follows has to be based on this layout design. No point in putting a nice large picture window in the side, only to discover that it will be covered up by a wardrobe. Obvious really, but still needs some careful planning. So, having bought the roof hatches and acrylic double-glazed windows and frames, it's out with the jig-saw. I decided that the modern looking slightly tinted acrylic as opposed to single glazed glass windows would be better looking and less likely to steam up with the Tibetan Mastiffs panting (no, not me and Jan) through the night, especially in Winter. (Yes, this van was going to be used out of season, in all kinds of weather). I also chose the sliding window option rather than openers, these could be left slightly open whilst travelling, a good source of free 'air conditioning' for the dogs in hot weather.

The next stage is not to be recommended if you suffer from any kind of a twitch, or have had a session at your local hostelry the night before. Make a plywood template to the size of each aperture, mark out in pencil, then drill a "start" hole. With a good quality Bosh jig saw, the first cut out went better than expected; the blade went through the metal like a knife through butter. I stood back, admiring my big hole in the side door, just hoping that it was in the right place. Point of no return, now, so out came the others. Then the four roof hatch vents, a bit over the top but really good ventilation is important, I reckon. The next part was one of the most satisfying, fitting the actual windows. Total transformation in just a weekend, when the van suddenly looks like a motor home (only from the outside, of coarse), as opposed to an ordinary panel van. The windows I used were Seitz S4, really good quality German manufactured units, coming complete with blinds and fly screens already fitted. The window is in two halves, the outer window and frame just pushes into the aperture, whilst the inner frame, screws into this outer frame, like a clamping action. It's that easy, if you have a helper to hold the outer section whilst you locate/secure a couple of screws. I decided to fit them "dry" at this stage (without any sealant), as they would be removed just prior to the paint job which was going to be applied. The longest job is making timber frames from 2x1, which I temporarily stuck in place with the aid of double sided sticky carpet tape; once the window is in, screwed up and clamped, it all holds together.

Part 3-Prep and Paint

It was at this stage I decided to have the exterior prepared and painted. I have seen so many conversions where the inside is finished, but due to maybe a lack of money or inspiration to finish the job, the outside looks so shabby, and often never gets done properly. After many visits and phone calls to various paint specialists, I finally got to speak to a guy called Mike at TW Mercedes Commercials, Batley, West Yorkshire 
(Tel: 01924-422 700). He sounded confident over the phone, and when I met him and described exactly what I wanted, I left hoping that his promised quote for the job would be reasonable and within my budget, as I felt I could trust this guy. He rang the next day as promised, and I accepted his estimate. TW would remove the double back doors, and fabricate and fit a solid panel, which would be contoured to match the exterior shape of the rest of the van. Their quote of under ?2K would include fully preparing and re-spraying the complete vehicle, and they would also repair the side passenger door and sliding door, damaged in a previous life. Three weeks later, I collected my van, and wow - what a transformation; Mike had done everything he promised, and more. I was delighted. How refreshing in this day and age to receive such good service, reasonable price and all on time...with a smile thrown in free...cheers Mike.

Part 4-Internal Construction

This section took quite some time, on and off, so I won't bore you with every detail. However, I basically framed the whole thing out, walls and roof, with 2 x 1 timber, fixed to the metal bearers using no 14 self tappers about 40mm long. The insulation was fitted, but rather than using rock wool or polystyrene panels, I used 30mm thick "Koolag", which had a reflective foil on one side; the same material as used in industrial roofs and buildings behind the corrugated steel sheets. I then lined the roof and walls with a special caravan wallboard, similar to plywood but with a nice finish. I had decided to avoid the more normal method used in van conversions by lining everything in sight with corded carpet, as I thought this might become a magnet for dog hairs, and can often look quite oppressive. A nice light airy look was what I was aiming for.

The cupboards and lower lockers were basically 2 x 1frames, covered with 9mm ply screwed firmly. Over this I glued on the finished surface, a special caravan ply with a nice medium oak surface. 

After various thoughts on what was priority, I had opted for a full width rear bathroom, complete with wc, washbasin and separate shower. The caravan we had used for ten years had a bathroom which was rather cramped, so large bathroom it had to be, at the expensive of some living space. Although it was a large van, it soon became apparent that room was at a premium, and many of the mental pictures in my head had to shrink somewhat. I needed to install a wardrobe, but that only left just over four feet for one of the beds. Now as I had no intention of sleeping all night with my knees up to my chin, I incorporated part of the bed within the wardrobe, the legs end. Sounds strange, but very room effective, and it works well. The cab roof was very high, and to fill this wasted space I installed a shelf, ample for bedding, pillows and sleeping bags, but would not have been high enough to take a bunk bed.

One small detail which gave me major headaches was where to site a locker for the gas bottles. I built this and re-built it a least three times, but finally deciding to spend yet more money, and have an external LPG tank fitted. which would hold up to 60 litres of gas, without compromising interior space. This was installed by a qualified fitter, one of the very few trades I did not undertake myself.

Part 5-Essentials

The fridge is a 12 volt only (rather than a three way 12v/240volt/gas), a "compressor" fridge made by Waeco in Germany. So far it has been very successful but ample battery power must be available, as it will soon drain the 12 volt system if not topped up by driving/mains charging every day. I usually carry a 600 watt Honda suitcase generator for topping up and emergencies, but this is bulky to carry inside, and a bit of a pain to lift outside every time one wants to use it. Eventually, I will fit an onboard electric start genny (Electrolux or similar) which will be bolted to the chassis, and fire up at the touch of a button. At over ?2k, this is a luxury which will have to wait.

On to the heating and hot water system. Option one, as in my caravan, was to fit a gas fire and blown air fan and ducts, which would require a flue through the roof, and a separate gas fired boiler, requiring another bloody great hole cutting in the van. 

Option 2, fit an Eberspacher diesel system, like  the truckers use. This would take it's fuel straight from the diesel tank, heat the water and  provide heating in the van. Complete with a time switch and thermostatic control, this seemed a better option. The added bonus was that whilst driving, the domestic hot water would be heated via the vehicle's engine coolant system, meaning that after a few hours drive, I could jump straight into the shower and enjoy "free" hot water. This was taken to an authorised specialist dealer to be fitted, although the two day job took three weeks, came back not working properly, and resulted in some very frustrating phone calls and return visits. After a few initial teething problems, I can honestly say that I am very pleased with the system, and glad I opted for this. I would not, however, recommend the company who fitted it, as I felt that my job was shelved whilst more 'important' contracts were carried out. Towards the end, I got fed up with false promises, and the  four or five trips down to Mirfield. 

It is an excellent unit, as I can attest to as I sat warm and cosy on a night 3000 feet up in the Vosges Mountains on my recent trip to France in November. There is a slight drawback over gas systems though, if your 12 volt batteries get low,( I have 2 x 110 amp in tandem) the thing shuts down. So it could become very cold, or you have to resort to starting up the engine to re-charge.

The gas cooker is a fairly basic 2 ring, grill and oven affair, fed from the onboard gas tank and quite ample for our needs. Who on earth wants to cook up a full Sunday roast whilst travelling anyway. Plenty large enough to boil a kettle, make toast and a good old full English fry-up.

Moving to the outside, I have included my external awning as an "essential". To be quite honest, I have hardly used it this year, but a most welcome option for shade for the dogs. Made by Omnistor, it is a 5 metre long model, which easily winds out and is set up in less than 3 minutes; none of the wrestling and struggling in the rain, like the caravan ones. I had this fitted at York Show by Broadview Blinds on a special offer, buy today, and they would fit it free in the car park.

Part 6-Luxuries

I reckon if you intend driving up to three or four hundred miles in a day, in what is after all a commercial vehicle with heavy springs, you need somewhere comfortable to park yer butt. Even in my Isuzu Trooper, I found that my back was starting to complain after a few hours drive. So good seats were called for. I visited Dick at the Van Shop down in Sittingbourne, Kent, where he showed me various seats, both from Germany and the US. The latter option, "Riviera" seats, looked and felt just the job. Checking them with my tape measure, they were almost four inches wider than my existing drivers seat, plenty of support under one's legs, had foldaway armrests, and deep stowage pockets in the back. We chose a material to match our upholstery, and even ordered two swivel base plates, along with three seats. The third seat would be placed behind the driver, acting as a third passenger seat, and when swivelled round, would be used as a dining seat, as  well as a place to sit back and relax. As promised the seats were delivered within 10 -14 days, and again with the help of TW Mercedes, were soon fitted into place. Wow, it was like driving a different vehicle, so comfortable.
Some people had said that if they were too comfy, then one might have a tendency to relax and sleep at the wheel. Well, I have to disagree, comfortable well fitting seats result in less fatigue and stress. The armrests take so much pressure of the arms and neck, the latter having been a problem area for me for many years. Four hundred miles seems like two hundred now, and they will recline back if I want a quick nap en-route ( I do stop the vehicle first, though!)

I hardly ever watch TV at home, but I must admit that a TV does give a very homely feel to a camper van whilst away. I chose a 10" colour Roadstar, which has a built-in video player/recorder. Now this did appeal to me, I could take away videos which had been waiting for me to watch over the months, and even play back the days video footage of dogs through the digital camera, and save it to VHS. Searching the Internet, I came across QED, and ordered from them at a much reduced price compared to the High Street shops, without leaving my desk. It was ordered midnight on Saturday, and delivered to my door on Tuesday morning-excellent service.

Chuba pictured (centre) on her recent trip to Alsace, 3000 feet high up in the Vosges Mountains(above)

Part 7-Finishing touches/Conclusion

Approx. 18 months into my project, I am almost finished, but still need to trim the drivers cab roof, fit cab carpet, and one or two little "snagging" jobs. Then I can sit back, relax and enjoy. Or can I? probably not, as every time I use it I start to wonder, should I alter this, or move that? Can I build an extension on the back? (yes, I really have considered this). Ah well, I suppose I will always think of ways to improve it, but on the whole, I am delighted with the finished product. The van is a dream to drive, helped by power steering, which really came into it's own on those twisty mountain road with hairpin bends in Alsace. 

I could just do with a bit more power on the hills - One hundred and ten horses keep her going nicely on the motorways at around 60MPH up to the legal limit; I even had her (yes, she is a bitch, not a dog) up to 80 on Whitwell-on-the-Hill in East Yorkshire (naughty, naughty), but coming up Pool Bank leaves me in second gear, 23 MPH and a trail of traffic resembling a New Years Eve Congo dance up me arse-end...........maybe a new turbo?..... or should I fit an intercooler?... or wonder if a bigger engine will fit? ...(or tie a team of TM's to the front, led by a cat).

Click on the thumbnail below, to see a sketch of the layout, for anyone wishing to undertake a similar project. If this is you, please don't hesitate to ask me any questions, as I know I would have appreciated some useful advice and tips; I went right in there blind.

If you have not got totally fed up with this page yet, click on the links below for more pictures.

Would I do it again? Dunno, at one time I said never, ever again, as the amount of time and money spent is not worth it. However, I probably would as I did get a great deal of satisfaction building my own camper van  ( er,motorhome, please). 

Actually, I have got my eye on an Optare bus, I bet that would convert like a dream; very low floor height, 8 metres long and wide...uhm!!

Happy Converting
Andy

    The merc has now been sold, and my new van is a Transit Jumbo. Hope to post progress and pictures in time.

Web design, text and photographs by Andy Briggs, Copyright © 2001.

Last revision on 07 January 2008 .