New Expert Build

Pathfinder100 · 2021-07-19 15:01:18

I have acquired an 06 Peugeot Expert 2.0 for conversion to a micro camper. I will be picking it up later this week. I previously had a SWB Transit that i converted, so I am looking forward to a new blank canvas. Initially its going to be a bed/bench seat and small cupboard unit with cooker/sink in the top. Toilet somewhere. 200w solar/30A MPPT/130ah AGM. Sometime in the next couple of months I will add the compressor fridge and diesel heater, and upgrade the solar to a single 295w Perlight panel.

I'm looking forward to picking it up and starting work on it. I am looking at a 3 week window to convert it. I already have most of the materials and wood I need, plus all the electrics kit and about 16m of 5mm foam/dual foil insulation.

Are their any quirks with these vans that i should be aware of?

kenbw2 · 2021-07-19 17:59:00

That sounds immensely exciting, that's a lot of solar! Make sure to post lots of progress pics

Many quirks, obvs. I look forward to hearing which ones yours has big_smile

Last edited by kenbw2 (2021-07-19 18:01:07)

Pathfinder100 · 2021-07-19 19:09:43

kenbw2 wrote:

That sounds immensely exciting, that's a lot of solar!

Not really in comparison to the Transit with its 400w primary solar array and 20w secondary (that trickle charged the VB). As long as I can generate through winter I'll be happy, even if it isn't at the same level. Its just having enough power to run everything. On 400w I could run a small computer, fridge, heater, lighting, etc. I do want to move up to a LiFePO4 battery or LTO battery somewhere down the line, probably no more than 100ah, but its a massive pain to do that upgrade and you need so much extra stuff (BMS, B2B, BatteryProtect, decent Victron charger), so its not high on the agenda.

I will probably be partially living in this van for a couple of nights every week, so it needs to be pretty squared away.

tee_cee · 2021-07-19 20:01:56

I was somewhat unlucky with mine, but worth reading https://dispatchexpertscudo.org.uk/foru … php?id=954
The only other thing is that split relay charging wont work because the alternator voltage droos below 12.7v when the ecu thinks the battery does not need to be topped up.

kenbw2 · 2021-07-19 21:54:53

Pathfinder100 wrote:

I do want to move up to a LiFePO4 battery or LTO battery somewhere down the line, probably no more than 100ah, but its a massive pain to do that upgrade and you need so much extra stuff (BMS, B2B, BatteryProtect, decent Victron charger), so its not high on the agenda.

I have this 75Ah LiFePO4 battery in mine, it juuuuuust about fits in the engine bay next to the 45Ah vehicle battery. I got a drop in for exactly the same reason, it avoids all the BMS, protections etc. Very pleased with it.

Pathfinder100 · 2021-07-20 02:35:42

tee_cee wrote:

I was somewhat unlucky with mine, but worth reading https://dispatchexpertscudo.org.uk/foru … php?id=954
The only other thing is that split relay charging wont work because the alternator voltage droos below 12.7v when the ecu thinks the battery does not need to be topped up.

So I guess i need to skip the VSR and go straight for the B2B then. Another thing to add to the to-do list. hmm

That thread of yours is a bit of an eye opener. Amongst the first things i intend to do to mine, will be a complete basic service, ie, change the oil and the filters. Might have to plug the OBD scanner in as well and see if any hidden horrors are lurking in the background. wink

At present the only fault I know mine has is the front brakes are binding slightly. So new discs, pads and a caliper overhaul, will be on the todo list at some point.

kenbw2 wrote:

Pathfinder100 wrote:
I do want to move up to a LiFePO4 battery or LTO battery somewhere down the line, probably no more than 100ah, but its a massive pain to do that upgrade and you need so much extra stuff (BMS, B2B, BatteryProtect, decent Victron charger), so its not high on the agenda.
I have this 75Ah LiFePO4 battery in mine, it juuuuuust about fits in the engine bay next to the 45Ah vehicle battery. I got a drop in for exactly the same reason, it avoids all the BMS, protections etc. Very pleased with it.

One of my possible routes was to go for a Sterling LiFePO4. They sell the old stock with new BMS for a fair chunk less than the brand new ones. I've seen 80ah on eBay for £385, 100ah for £450 with 3 year warranty. The other possibility is to go all out and order 4x 280ah 3.2v cells and DIY a 4S battery with a 12V 4S 100A Daly BMS for around £700 (cells can be sourced from a couple of people on Will Prowse's site/forum).

Im not decided on Lithium yet. But if the alternator wont easily charge via the VB i might look into wiring the VSR directly to the alternator and if not, I guess go straight for the 18A Victron Orion Charger B2B for £155 (which futureproofs things).

Last edited by Pathfinder100 (2021-07-20 02:36:24)

tee_cee · 2021-07-20 08:35:27

Just looked again and yours is 06, so none of what I've said applies to you since my van is 2015

vaz2121 · 2021-07-20 10:02:06

tee_cee wrote:

Just looked again and yours is 06, so none of what I've said applies to you since my van is 2015

Only real issue I can envisage with a 2.0 HDI now if it's not been discussed before [i.e. my 307 Rapier debarkle] is the usual prior abuse e.t.c. being and what a Van gets......
If you've satisfied yourself there and with Van being 2006 [As pointed out by tee-cee] and the likelihood to have or not a DPF [FAP] ..........

My only real concern now would be Electrical wiring in engine loom controling engine functionality with it aging and it now being 15 years old.........
With all those heat cycles looom becoming brittle and breaking or getting cruddy high resistance connections giving weird WTF symptoms ............

But don't let that worry you so.........
It doesn't apply to all aging HDI's ..............

Pathfinder100 · 2021-07-20 12:31:46

Yeah, I think the wear and tear end of it will just happen. I had the same on the Transit, mainly with the towbar electrics which in the end I just disconnected since I don't tow things.

What do you guys prefer for interrogating the ECU? I see the software is different for these vans. I hoped with the Scudo being similar that multiecuscan would have worked, but their website says no.

tee_cee · 2021-07-21 13:15:38

I guess it depends on how far you want to go. The lexia interface and diagbox clones are is the standard tool. There is a lot of marketing around software and hardware versions but for a 2006 van probably any version will be ok. The bigest issue is running the software, because it wiil not work on windows 10 or any 64 bit system.
I installed mine (8 years ago) on an xp vmware install and it took ages to go through all the upgrades etc. Maybe easier now.
For simple error codes and parameter reading the Fap(lite) app is good, apart from lack of updates and support from the developer. Sadly this is what happens once the money starts coming in - like Torque app.

Pathfinder100 · 2021-07-22 14:54:54

Well I picked it up yesterday and drove it back home. It took a few hours, mainly due to rush hour in Southern Essex, but I got home at 10ish.

So things I know need sorting:

1. Turbo / Boost pipe is probably split. Whenever the turbo kicks in while accelerating, smoke pours out of the exhaust. When the turbo is not running, no smoke is produced, ie, when I keep the RPMs low. Had a problem like this on a mondeo a couple of months back and discovered a large split on the boost pipe. it might be the same on this van.
2. Bonnet catch is non-existant.
3. Some rust needs dealing with.
4. Steering has a noise when turning the steering. i think maybe the strut mount bearings or possibly the lower ball joints or track rod ends.
5. Timing belt needs a change.
6. Need a new aerial for the radio.
7. Need to do some internal rust painting.
8. need to remove the bulkhead.
9. Odometer doesnt function but everything else does (speedo, fuel, temp, warning lights, etc). i can get this figure from the ECU so its not a big deal per se.
10. Gearbox is pretty worn and clutch has a really high biting point.
11. Drivers side keyhole spins around endlessly. Common fault as i remember and needs a new clip to hold the lock in place.

Aside from that the fuel economy is staggeringly good. I went from Harwich area to Sheffield on just over a quarter of a tank of fuel. Up the M11/A1 to Worksop and cut through on the A57. All driven at roughly 50-60.

Last edited by Pathfinder100 (2021-07-22 22:06:39)

Pathfinder100 · 2021-07-23 20:42:40

Day 1: Removal of Bulkhead, removal of window cleaning kit installed in the back, have also discovered the spare wheel and found a bunch of rust that needs dealing with.

Discovered the flashing Stop light doesnt mean the van is currently not moving.:P I think its flashing because the intercooler pipe has a hole somewhere judging by the oil leaking from it. Easy to fix. The whirring noise on the steering is at a guess the power steering pump, or maybe its low on fluid, either way that something else to check in the next coupe of days. Its currently on my ramps and will remain there until I have completely rust proofed the underside (bits I can get to). There is a bunch of car parts that are also rusting, so will also give those a lick of hammerite and probably kurust. God the wheels are in a bit of a state. Totally rust everywhere. Will be going wire brush and sandpaper on them in the next 5 days and then they will get a lick of black hammerite. All in all there are a few things to do. Oh and the airbag light came on, no idea why. My basic OBD scanner will get plugged in, in the next couple of days and the error codes written down so I can find out what broken. Then in the next couple of weeks I will try and get the DiagBox/Lexia software and kit as I think it might be a worthwhile investment. smile

Pathfinder100 · 2021-07-24 23:20:09

Day 2: Rust removal / Hammerite. I have spent a few hours just painting over rust. The worst part was the metal box section at the rear right and left sides. its the one that JohnDragon had to rebuild/weld in his Youtube videos. Thankfully mine is in slightly better shape. It isnt fully painted yet as the amount of dirt and crap in it took nearly 20 mins to clear and I got bored and went off to paint the spare wheel carrier as I had some neck pain from laying awkwardly. Eventually i came back and painted it maybe 25%. Will finish it tomorrow. Thats the nearside one. Haven't even touched the offside one, its mega full of crap.

I am also worrying over the turbo problem. Is it a pipe split between the manifold and turbo, or is the turbo shafted? That is the question. A refurbed turbo is sadly far beyond my budget and getting a secondhand one, while affordable may not be a solid fix for the problem. Could I remove the turbo and turn the engine into a badly configured old school diesel minus the turbo and EGR? I don't know. Not to mention the need to remove the exhaust, cat and subframe to get at the Fkr. I have no pit or lift, but do have axle stands, bottle jacks and ramps. From what I've seen the sub frame weighs quite a lot. The job could turn into a large nightmare. Still after watching a bunch of Youtube videos, it may be possible if I have to do so and an upside is i can do some anti corrosion on the subframe. Anyway, this is a backburner job. I am rust proofing the underside currently.

On a side/crazy note. Will a 1.9L Diesel engine fit in a 2.0 Diesel Engine bay?

Signing off for today and drinking more beer. Tomorrow is general cleaning of the inside, which is mucky.

kenbw2 · 2021-07-25 21:10:12

Pathfinder100 wrote:

On a side/crazy note. Will a 1.9L Diesel engine fit in a 2.0 Diesel Engine bay?

Yes! Expect a massive drop in power with the DW8 1.9D. The 1.9TD XUD is closer (but still less)

Pathfinder100 · 2021-07-26 00:21:34

Can't be any worse than driving up the A1 the other day trying to overtake an HGV up a hill, without the turbo functioning. I managed 63MPH. Didn't realise the van was essentially in limp mode at the time, anyway that's Tuesdays problem. I think its the pipe running from the manifold to the turbo. If it isnt then i will be investing in Diagbox/Lexia and trying to work out what has gone kaput (presumably the turbo). I have found one for a reasonable price with a 12 month warranty, assuming it fits, not that i'm sure I could fit it. I'm guessing i would be looking at a big bill to get it done at a garage. If the quote was high enough i would probably try and do it myself. Worst case I suppose I could do the legwork of removing everything and then use a mobile mechanic to handle the rest.

That video is very informative. I could probably do most of that, but don't have an engine crane/winch. The thing that would scare me the most is actually making a new loom. Everything else is undoing things, taking lots of pictures and watching youtube videos. I do like the idea of having an old school diesel engine, much like my first car which was an E Reg 1.6D Fiesta. It was a good runner and as long as you dropped the oil every 6 months and replaced the filters it never missed a beat.

Pathfinder100 · 2021-07-27 17:40:10

Some pictures.

The beginning of the conversion.

The water tank in the back.

Bulkhead and tank removed and preparing for painting.

I have now completed the back painting that i planned to do, to address some rust i had found. It has been covered with Hammerite. Both sills have been painted with the same. Any pits, scrapes or scratches inside the van and outside on the bodywork have been covered with smooth white Hammerite. The front sub frame still needs some work and some other parts of the main frame. Then underbody seal everything.

kenbw2 · 2021-07-27 18:24:59

That's a huge water tank. Is that living inside or somehow going underneath?

The rest of the bulkhead will come out if you want to. It has a few spot welds, and the glue can be taken care of with a bit of abrupt force.

Also, you're gonna be trapping your hands all the time now you've removed that warning label roll

Last edited by kenbw2 (2021-07-27 18:25:52)

Pathfinder100 · 2021-07-27 18:42:36

kenbw2 wrote:

That's a huge water tank. Is that living inside or somehow going underneath?

Not a chance in hell. The van was a former window cleaners van and was kitted out for such a job, including that 500l tank, a high pressure pump and a 130ah battery (that he couldn't even be bothered to wire to a VSR). But that will all be getting sold in the next week or so. I already have a much better leisure battery (Leoch SLCA 130ah AGM)

As for the bulkhead bottom, i might leave it in. it affords me a place to bolt the bed to that is fairly sturdy. The two passenger seats are also staying in on this build. At least for now.

My plan is something like a bench seat bed on the passenger side and a small unit on the otherside with a cooker and wash basin. Table integrated somewhere. 12v electrics, diesel heater, etc. Really low key and minimal. Also will have mains power, but via one of those camping all-in-one units (3 sockets. usb charger, circuit breaker). I just need it to run a charger for the leisure battery if i've opted for EHU at a site and maybe a kettle. Or even an oil filled radiator if im using it in the middle of winter. But in the summer I doubt I will use mains very often. Whatever goes I want to keep the roof (plus any solar or vents) to less than 2m, so I can get into all those car parks with 2m barriers.

kenbw2 · 2021-07-27 23:00:27

Pathfinder100 wrote:

My plan is something like a bench seat bed on the passenger side and a small unit on the otherside with a cooker and wash basin. Table integrated somewhere. 12v electrics, diesel heater, etc. Really low key and minimal.

Dammit, your "low key" completely describes my full time home yikes

Pathfinder100 wrote:

Whatever goes I want to keep the roof (plus any solar or vents) to less than 2m, so I can get into all those car parks with 2m barriers.

This is my absolute favourite thing about these vans. I've squeezed (sometimes very narrowly) under many a barrier

Last edited by kenbw2 (2021-07-27 23:00:38)

Pathfinder100 · 2021-07-28 13:05:05

kenbw2 wrote:

Pathfinder100 wrote:
My plan is something like a bench seat bed on the passenger side and a small unit on the otherside with a cooker and wash basin. Table integrated somewhere. 12v electrics, diesel heater, etc. Really low key and minimal.
Dammit, your "low key" completely describes my full time home

It may become my semi, full time home from September. Once I get back to college I plan to travel back and forth as little as possible. Ideally i will find a campsite near college and commute while I'm up there. Coupled with a gym membership so I can get a shower everyday and work out. I just need to minimise costs this year as much as possible.

So anyway, even though i still have this wastegate solenoid malfunction, the van still drives fine and if I keep the speed to 50mph (drive it like a lorry, slow and smooth) or so it doesnt smoke. Obviously come next MOT it will need to be fixed, but that is not until next year. So for now my only immediate concern is the timing belt. Once thats done, we'll see.

I'm going to start building the insides this week. Its going to be carpet lined because I can't be bothered with anything more complicated. Cheap floor tiles for the floor (or lino if I can find some). Don't have the diesel heater yet, but will do at some point.

cliffo · 2021-07-28 22:52:16

Pathfinder100 wrote:

Cheap floor tiles for the floor (or lino if I can find some). Don't have the diesel heater yet, but will do at some point.

I've used lino/vinyl and bought a couple of 'economical' memory foam bath mats to add a bit of washable comfort

https://smile.amazon.co.uk/dp/B07TVBZYM … ZR8DFHC3R0

OAT · 2021-07-28 23:07:11

I quickly and roughly chucked some of those "EVA" interlocking gym mats in mine over two yeas ago now to cover up the stained carpet until a better replacement. I only expected a couple of months out of them
After hard use virtually every day since then they are still tolerable (to me at least". The places they have moved or split are down to my bad fitting. They have also compressed where the hardest wear is but after seeing the cost of any decent alternative, I think I will use them again.

They need gluing with the correct stuff all round and I think a good coating of suitable sealer would be a good idea.

Advantages being, easy fit, cheap, insulating and warm underfoot, easy sweep.

Pathfinder100 · 2021-07-29 00:28:22

Tomorrow is insulation day. I have 5mm double foil to go, pretty much, everywhere. Also have 5m2 of floor tiles.

Next bit of fun will be to try and get a 16mm cable from the load area to the engine bay, for the VSR. I am guessing some cable runs will exist behind the dash on the passenger side. Failing that i'll drop it under the vehicle and run it at the top of the nearside sill in conduit.

kenbw2 · 2021-07-29 17:19:41

I fed the wire through the passenger wing and in via a grommet near the door hinge

Last edited by kenbw2 (2021-07-29 19:26:07)

cliffo · 2021-07-29 23:12:00

Pathfinder100 wrote:

Next bit of fun will be to try and get a 16mm cable from the load area to the engine bay, for the VSR. I am guessing some cable runs will exist behind the dash on the passenger side. Failing that i'll drop it under the vehicle and run it at the top of the nearside sill in conduit.

If you don't have electric windows then there's a useful 'spare' 30A cable at the interior fusebox...

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#1 2021-07-19 15:01:18

New Expert Build

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Re: New Expert Build

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