Transit Custom EMTB Camper van conversion

[Nickolp1974]

So just after the 1st lockdown i decided to buy my self a van to convert. I did have an estate car but did not want to leave my emtb on the back even locked up. Often go to the lakes etc for long weekends hiking in the mountains but i've never taken my bike which influenced my decision to get a van. Ended up with a 65 plate high roof long wheelbase which is perfect as i can still park it in a standard car park space. I considered a sprinter or crafter but there just to big for my needs. Although space is limited especially with the bed down it all works and i have everything that i need and more. I've only used it 3 times this far due to being flat out at work and now of course another lockdown!! but those 3 times were great in sussing a few things out, what we still need and what we dont.

specs
2x 180ah batteries
1000w pure sine wave converter
aili battery monitor
240v hookup
12v power
USB's
5KW diesel heater (overkill)
swivel for passenger double seat
rock n roll bed with futon matress and memory foam
electric coolbox which chills 18c below ambient
toilet
combined sink hob with tap
external waste water
internal lights
roof vent
awning
12v jet wash for bikes
Awning
Table and chairs etc etc

The van originally was just a normal panel van with no windows etc, so it all got stripped out cleaned, bulkhead removed windows and rooflight installed. then onto sound proofing which took ages along with the insulating and i used products from Dodomat Dodo Mat Automotive Sound Proofing and Insulation the noise levels inside the van are superb, even with the wind howling and rain i can hardly here a thing and the van needs minimal heating to keep warm, oh the van walls are covered in lining carpet and altro flooring on the erm..... floor! No idea why i went for a 5kw heater, not actually used it out in the field yet but im guessing it wont be on for long. Overall the conversion took me about 6 weeks of weekends and nights after work which aint to bad cos i've had to learn everything along the way.

So i sized the batteries so it would charge 2 e bike batteries off grid but thats rated at 180w for 4 hours but the watts drop while charging so it may do 3 full charges while also supplying power to the rest of the van.

Oh and the bike securing was done with 19/15id tube with 15mm pipe clips and a block of wood for the front and tie down straps for the back wheel and the bikes are rock solid in transit, stems have to be loosened to get handle bars in but that takes all of 2 minutes to sort.

I could go on forever about it but i wont bore you!!! i just cant wait to use it fully and get away more often.

 

[deksawyer]

Great job, well done.

 

[The Hodge]

Thats fantastic ..well done !
( I'm extremely jealous not only of the finished van ..but your skills in building it too)
Hope you have lots of fantastic adventures ..

 

[Nickolp1974]

Thats fantastic ..well done !
( I'm extremely jealous not only of the finished van ..but your skills in building it too)
Hope you have lots of fantastic adventures ..

Thanks, i enjoyed building it and learned alot. still doing bits as i go, dropped the fuel tank today to put an auxiliary fuel line in for the heater, really dont like working under vehicles but got there in the end.

oh if anyone has any tips to get rid of the carpet spray adhesive residue, shoots everywhere that stuff!! would be most appreciated

 

[Frankieboy]

Awesome job job there fella, not at all bad for someone who ”learnt along the way”

 

[Trig]

I stuck the bubblewrap foil insulation to the roof of my custom with it... can confirm it gets everywhere. And if you look up at the right moment, it even gets in your eyes!

It looks great. Would love to do similar, but got to keep it fairly empty for work use. Just got a camping bed and a table built into my shelfs.

Did you insulate behind the carpet or just carpet straight on the van?
I may steal that bike stand idea also... or be inspired by it rather

 

[Nickolp1974]

I stuck the bubblewrap foil insulation to the roof of my custom with it... can confirm it gets everywhere. And if you look up at the right moment, it even gets in your eyes!

It looks great. Would love to do similar, but got to keep it fairly empty for work use. Just got a camping bed and a table built into my shelfs.

Did you insulate behind the carpet or just carpet straight on the van?
I may steal that bike stand idea also... or be inspired by it rather

Thanks, everything is sound deadened(deadmat hex) and insulated. Ceiling, floor and rear is insulated using dodomat superliner 12mm sticky back stuff and the doors and sides also use dodomat thermo fleece and then ply lined over the top before carpeting.
the stand thing works well, there fixed in place with just screws and washers underneath, i may slot them though to adjust for different bike lengths.

 

[Trig]

Ah i didnt notice the black stuff, thought you had used the foil bubblewrap thats on your wheel arches.I used similar stuff, supposed to be equivalent to a certain thickness of glasswool or pir board, but ive not been away since last september when i fitted it, so not sure if its made much difference.

Can get pretty cold in them without it though, i know that much...

 

[Nickolp1974]

for anyone interested, i used the van batteries to charge my ebike batteries. 2 shimano 8010 504wh batteries were used.
charge states % left
2%
14%
45%
48%
this was after 2 rides using both batteries and charged up on the same van charge 127Ah was used. For this test i used the newer and slower shimano charger.
Happy with this as that means 5 full bike charges(2 already charged) off grid and still leaves enough juice in the van for everything else that requires power. should be good for a nice 3 day adventure, well 2.5. If only this lockdown would lift!!!

Also got heater finished last week while isolating, had to drop fuel tank etc. kicks out some serious heat, should be nice and toasty in the midst of winter

 

[Letford]

Brilliant job, I’ve just picked up a lwb T5.1 Hightop and will hopefully converting it similarly to this ?

 

[Nickolp1974]

Brilliant job, I’ve just picked up a lwb T5.1 Hightop and will hopefully converting it similarly to this ?

Thanks, nice post up a build log, always good to see other folks idea's

 

[Waynemarlow]

Thanks, nice post up a build log, always good to see other folks idea's

Do make sure guys you go for the HiTop versions as these are the only ones now you can get derestricted from 60mph to 70mph at the DVLA.

 

[Letford]

 

[Landy Andy]

oh if anyone has any tips to get rid of the carpet spray adhesive residue, shoots everywhere that stuff!! would be most appreciated

To get rid of the glue I use petrol on a rag, or if the smell is going to be a problem, brake cleaner.
I use these mount in my camper.

Cyclestore.co.uk

www.cyclestore.co.uk

You may also struggle in the summer with the amount of power you coolbox consumes, but swapping to a 12v compressor fridge will use a lot less power and also be a “proper” fridge not just temp below ambient, although they obviously they come with a price.

 

[Nickolp1974]

To get rid of the glue I use petrol on a rag, or if the smell is going to be a problem, brake cleaner.
I use these mount in my camper.

Cyclestore.co.uk

www.cyclestore.co.uk

You may also struggle in the summer with the amount of power you coolbox consumes, but swapping to a 12v compressor fridge will use a lot less power and also be a “proper” fridge not just temp below ambient, although they obviously they come with a price.

thanks for the tips Andy, i'll try some brake cleaner! as for the coolbox/fridge, i need to check for power consumption etc when i can actually use the camper!!

 

[Landy Andy]

thanks for the tips Andy, i'll try some brake cleaner! as for the coolbox/fridge, i need to check for power consumption etc when i can actually use the camper!!

Yes. You won’t be getting much use currently, and the cool box would be ok, but not so in the summer.

Im not getting much use of mine either

 

[Zimmerframe]

Yes. You won’t be getting much use currently, and the cool box would be ok, but not so in the summer.

Im not getting much use of mine either
View attachment 53108

Your DIY conversion is far more impressive than @Nickolp1974's . Especially when we look at your "Before" picture :

 

[Zimmerframe]

Amazing man! Wish there was a time laps YouTube video.

bambam's weekend camper ... you can take the boy out of America, but you can't take America out of the boy ..

 

[Zimmerframe]

I want to have a small ammo reloading room where I can make my bullet loads for my long rifles. Then snipe my food from the top.

I looked at the Earthraper last year .. it's just ENORMOUS ! and HEAVY !

Anyway, it's not you .. This is much more you :

Obviously towing one of these, you can't take your lady out for dinner on the roof mounted quad :

Though you could be right with the yacht option giving you more for your money - Genius ! :

 

[Zimmerframe]

Yeah. The roomers are beasts for sure!! Real issue is:
Hey honey should we buy a bad ass man Mobil sniping home or a yacht? We all know that answer. But good news is these 20 year olds will look damn good on a yacht for a good long time. God bless ‘em

that car is beautiful!!!’ I Love AMG. But I think I’ll get a Toyota next or maybe Tesla. It’s not really wise to get groceries with more than 500 horsepower.

My god man ! You're in Germany !!! That's not an AMG it's a Maybach ! That's you off the invitation list !

Not wise with more than 500hp ? But you'd consider a 1000hp Tesla Plaid with 0-100kph in 2.1 seconds ..

Don't buy a Yacht ! Everyone buys a yacht .. What do you see when you drive past a Marina .. 10000000000000000000 Yacht's tied up because no one can be bothered actually using them. It's like driving past a photo album of bambam's ex's !

Buy a €100 Decathlon Inflatable floaty anything .. it will be just as much fun and she'll look just as hot on it !

 

[jimbob]

Only just seen this. What an awesome build! Very nicely done.

I've just had a quick look at vans on auto trader, they're a bit more expensive than I thought.

 

[Nickolp1974]

Only just seen this. What an awesome build! Very nicely done.

I've just had a quick look at vans on auto trader, they're a bit more expensive than I thought.

yeah the likes of amazon etc and home build campers have driven the price right up currently. I was tempted to sell and do another but a replacement van is too expensive at the mo.

 

[dobbyhasfriends]

@Nickolp1974 - I am about to do something similar but I use my van for work so I cant take any room in the back up.
I am planning on doing it all under the passenger seat and on one 110ah battery with the possibility of upgrading to two batteries in the future.
I was going to get a standard kit like this: Battery to Battery Charger 12volt 30amp with AGM battery. Kit 63
and a 1500watt inverter - EDECOA Pure Sine Wave 1500W 3000W Power Inverter 12V 240V LCD 2*2.1A USB Ports 764880624854 | eBay
but ive never done this before and its pretty much only for charging bikes and tool batteries.
would you say thats enough power for charging a couple of 700wh batteries or overkill on equipment etc?
my calcs say that enough to charge both batteries once and thats it..

 

[jimbob]

I would say the inverter is overkill, but the batteries not so. A bigger inverter won't hurt, but may be less efficient.