The Dispatch | Expert | Scudo Hub

Hi folks, just before lockdown I bought my 2004 Dispatch 1.9 hd to throw the mountain bikes in.  Then, being furloughed, I had a bit of time on my hands and thought I'd see what I could do as a low level conversion.  Nothing hardcore, just something we could overnight in, or even take to festivals.  Here's the story:

Initially I was just going to have two benches, with a gap in the centre.  Then I realised we'd be better served with a side door being utilised, so I went with that setout:

Next task was to make up the frames for the benches, used 38x38mm softwood for that, then clad with 18mm MDF.  Next time I'll drop that back to 12mm MDF, the 18mm is overkill.  We'd worked out what we'd need to take on a typical trip, and this would give us enough storage.

After getting them in I thought they were a smidge big, so out they all came, and I cut them down to give a bit more footwell. 

The van had been a plasterer's van, so needed a deep clean.  That took some time! But at least it was fully ply lined.  Took all the panels off to be carpeted, so next task was to stick on some dead mats.  The dead mats were money well spent, the improvement is instantly noticable. 

I also ran wiring for USB chargers to both sides, reading lights over the back doors, downllights to the roof, a voltmeter, 12v outlet and some super bright LED lights (just in case)  Had to cut a bit of the steel away in places, but nothing too drastic.

For flooring, I installed two layers of 3mm foam underlay, then one layer of 5mm fibre underlay over the ply floor, then laid laminate.  Probably would use vinyl next time.  I had a leak on a recent trip and had to lift the lot!

Next stage was the insulation.  I decided to use two layers of foil backed sound deadening underlay.  It was really nice to work with, and appears to have worked well.  There's two layers under the ply floor, although I'd expect that's been reduced to a couple on mm!! At this stage I carpeted any of the white steel body that would be visible once the ply had been reinstated.

As a quick aside, I installed some leather, electric seats from an XF Jaguar, new gerknob and boot, and a new blue tooth streo and a reverse camera.  I  used the existing seat frames, but cut down, then bolted / welded unistrut for the new support.  The wiring was pretty simple, just two live feeds to each seat.

For switch back plates I used some thin ply, and carpeted. 

The storage / seat boxes got a covering with smoke carpet, wish I'd gone for anthracite here.  It marks easily!

I wanted to carpet the roof, so needed a single panel.  For this I made a template from cardboard, then marked and cut a sheet of 6mm ply.  Tricky one, but worked out well.

Covered that in anthracite to have a break from all the light grey.

I had a bit of anthracite carpet left over, so I pulled out the front headliner and give it a birthday treat.  Gave me the opportunity to fix some dead mats on the roof too.

I rescued some 18mm ply from a skip and used it for the table, here it is after the first coat of stain

Getting all the electrics in was fun, it's always nice when these things work!

Next was time to make the cushions, which I wasn't exactly looking foward to! My step daughter had just finished Uni, so I took a bread knife to the matress! Below is a first fit picture.  I thought it was too high, so I cut them all down.

For the covers I just bought some fabric off eBay.  I'm no upholsterer, so I cut ply 20mm smaller than the foam, then wrapped like a birthday present. Plenty of staples later, and that's what you see.

The table support was 25 quid on eBay, and does the job nicely.  I used some pine dowell for a curtain pole, and some £7 curtains from ebay. Put it all together and it looks like this (note wife input with soft furnishings! )

The extra cushions you need for the bed make the seat cusions stick out, but you don't notice when you're sitting on there.  Since finishing, the better half and I have toured the north of Scotland, Northumberland, and had a long weekend in the Peak District.  The seat boxes have ample room for all our dry food, drinks, clothes, bedding, gas bottle, camping kit etc. all that worked really well.  Owing me a meagre £1500 for purchase and conversion, I'd say it's paid for itself already! Happy Days!     

Hi all

Wonder if anyone else has had this? My 2004 Dispatch drives like new (well, close to  ) but 5th loves to pop out.

Not fully in to neutral, but just out of gear. Also, only happens when coasting, never with any acceleration at all.  Even a little pressure on the stick prevents it.

I’ve been living with it for a while, but we’re  not long back form the Scottish Highlands where the many hills were making her pop out every two minutes!

Any thoughts??

Hi folks

Has anyone swapped their steering wheel for something a bit more sexy? Thinking leather, and a bit more girth.......

Any tips appreciated