Peugeot Expert 55 Plate - MY VANSION

Hywelius · 2016-12-03 23:43:38

I'm converting my 2005 Peugeot Expert I picked up into a camper for surf trips! The plan is, it'll be more than just a day van for me and thought this would be the ideal platform for me to show my progress / pitfalls! My ears are open to any advice on the process as I'm new to converting and - likewise - If I can offer any to anyone else taking on something similar I'd be happy to!

Hywelius · 2016-12-04 00:00:02

Time to strip it down and find out what I've bought!
What lies beneath:

I removed my seats to try and remove the bulkhead - Eventually got it out after cutting through a few welds and ALOT of super strength seam sealer, roped in the help of a friend with a reciprocating saw which made light work of it. My plan was to put a drivers swivel seat in for now to see how much space I'd have to play with in the back, but, The one I bought (labelled for use with Peugeot Expert 2002-2006) unfortunately didn't fit ...to be continued - I have some photos of this to follow.

Before: (I think i've read somewhere this black box thing is a 'pressure' vent of some sort for when the doors are slammed - I may be wrong)

After a clean/lick of paint:

Casper · 2016-12-04 00:07:29

Nice an clean. Dont think its a weld on the bulkhead. More a strong resin and sealer so spilled liquid does not get into the cab. Two bolts and a big hammer took mine out. Did you buy a whole drivers seat or a swivel plate? Most plates you need to re drill holes and if you bought the whole seat cant you use the new seat and swivel but your base?

Hywelius · 2016-12-04 00:35:18

Casper wrote:

Nice an clean. Dont think its a weld on the bulkhead. More a strong resin and sealer so spilled liquid does not get into the cab. Two bolts and a big hammer took mine out. Did you buy a whole drivers seat or a swivel plate? Most plates you need to re drill holes and if you bought the whole seat cant you use the new seat and swivel but your base?

I had a couple of bolts on either side too yeah.

The swivel - the one I bought was 400mm wide from bolt to bolt centres and kind of fit front to back, but my seat runners are 384mm
It looked to me like it wouldn't be possible to fit at all - even with any modification:

I returned that one - and they said they may have found one that might fit:

This one would need some holes drilling in as shown below I think - so it's still not a guaranteed fit. *EDIT* ( the holes I would need to use would be the 244mm holes - as the holes on the actual seat wouldn't be long enough for the 330mm ones)

I'm leaving it for now as I'm beginning to think that because I have the double passenger seat - the drivers seat might struggle to spin anyway, also with the handbrake clearance!
Potentially in the long run i'll look into 806/Ulysee seats or something. I had spotted a ulysee non runner for sale the other day for cheap - but still unsure as to whether those 2 captain seats would easily (enough) replace my double bench seat. It's early doors for me and might be a long term goal - not sure. It's early doors, thought I'd do my research first and make sure a swap over like that would be within my skillset!

Last edited by Hywelius (2016-12-04 00:39:43)

Casper · 2016-12-04 00:52:31

I had double passenger and binned for single from a scudo. Different upholstery but who looks at the seat when they are sitting on it

Your van is even clean under the seat. You OCD big_smile

Last edited by Casper (2016-12-04 00:57:51)

Hywelius · 2016-12-04 01:03:05

Thanks! that's promising, I'll def be keeping my eyes peeled for a single passenger (*seat) big_smile .

I was thinking it had to go above the runner to clear the handbrake but I did consider the lack of ability to adjust if going above the runner. I might go for the other one eventually and give it a try whichever way will fit/work. I'm not really getting my head around how it would clear the handbrake if you go below the runner tbh.

Casper · 2016-12-04 01:15:34

I am sure someone the 806/Ulysee handbrake could drop while still on (Unsure) But leave the van in gear and just drop the lever to spin chair. TBH the layout determines if your need one on the drivers side. I only used mine twice when i went away. The passenger was the one i used most. I only turned it as i could. My next van dont think i will be bothering as i may be putting the cooker in teh area behind. Page eight is my seat in use, storage smile i sat on it once to take a picture

http://mytintent.blogspot.co.uk/p/blog-page.html

Casper · 2016-12-04 01:20:09

BTW there is nothing wrong from taking seats from another van like a transit or whatever and drilling holes in the floor to mount them. You just need to put load bearing plated under the bolts under the van. My single passenger did not fit the bolt holes from my double so had to drill another two holes.

Casper · 2016-12-04 01:46:14

Ah ha. Just remembered where i got the extra height. You will see in the floor where you took the passenger seat out you have four plastic spacers. I used them to gain height from the top half of the swivel. Think on the drivers seat i just used larger bolts and a couple of nuts.

Anyway, away to my bed but keep us posted on your progress as its always interesting reading about others progress and ideas/layout of the vans.

Hywelius · 2016-12-04 01:53:47

I have read about the load bearing plates yeah. I'm looking to have a full length folding bed behind the drivers seat at the moment with LH door access. So, was going to have it (bed) the same height as the swivel to extend it a foot or so. I'm sure I could manage some drilling etc. but if there's an easier fit I would be more inclined to do it. Just looking at options more now rather than rushing into getting the swivel!

I Insulated a bit today! Next step is the floor!

Can't take all the credit:

'Mock' fridge cardboard box - potential placement by the door (venting may be a problem next to the sliding door!?)

monkeynut · 2016-12-05 23:55:33

I did alot of reserch into seats when sorting out mine, i decidid to bide my time and wait for some out of a 806 im glad that i did asthey are designed to fit! well made and come with aremrests :-) , Casper the handbrake lever drops down you pull up then pull on the button,, but when swapping seats make shure its in gear as the brake mount is on the base

Casper · 2016-12-06 00:41:25

monkeynut wrote:

I did alot of reserch into seats when sorting out mine, i decidid to bide my time and wait for some out of a 806 im glad that i did asthey are designed to fit! well made and come with aremrests :-) , Casper the handbrake lever drops down you pull up then pull on the button,, but when swapping seats make shure its in gear as the brake mount is on the base

Naw i am fine as mine just skims but i like the handbrake to work on 3/4 clicks. I presumed the 806 had a 2nd drop. Handbrake works as normal but a 2nd drop up the shaft allowing it to drop but brake stay on.

Hywelius · 2016-12-06 01:34:58

Yeah I think I will be keeping my eye out for something 806/synergie/ulysee if I can hold out definitely sounds good! Also any single scudo/dispatch/expert single passengers seats. Thanks for the input!

I did a bit more insulating and got my new ply down over the weekend:

Floor insulation and Ply came a bit short between the wheel arches unfortunately - Insulation due to measuring on the old van wood (which doesn't follow the ridges in the van floor, of course!) Ply was just a misjudged cut. Still, will be hidden so not too bothered. Happy with how clean it's looking. Road noise is alot quieter now with the deadening effect of having something lining the van which is ace.

P.S. Side note...Anyone know how to rotate an image in my post?

Casper · 2016-12-06 13:07:19

Hywelius wrote:

Anyone know how to rotate an image in my post?

Aye, chuck you iphone in the bin and buy android. Way better big_smile You got a google account? you get storage for pictures with your account and after uploaded you can edit them and rotate. Think you can do it in photobucket also but that site has been painfully slow of late.

Oh another one that lets you rotate after you upload is https://postimg.org/

Having a google account your phone can upload just after you take the picture. Unsure if your iphone would allow this but might be worth looking at. I al presuming you are using iphone and not android and taking the pictures in portrate.

Hywelius · 2016-12-06 21:01:37

Casper wrote:

Hywelius wrote:
Anyone know how to rotate an image in my post?

Aye, chuck you iphone in the bin and buy android. Way better You got a google account? you get storage for pictures with your account and after uploaded you can edit them and rotate. Think you can do it in photobucket also but that site has been painfully slow of late.
Oh another one that lets you rotate after you upload is https://postimg.org/
Having a google account your phone can upload just after you take the picture. Unsure if your iphone would allow this but might be worth looking at. I al presuming you are using iphone and not android and taking the pictures in portrate.

I'm on android already haha! I'm uploading from Mac. I can rotate images perfectly fine, but when I upload portrait ones to this particular site it rotates them and adds it in landscape (wrong, like the ones of the ply'd van above). Adding some HTML into the 'img' tags doesn't work. Won't let me. Ah well not a massive biggie. nevermind - maybe this is for another thread or even forum. Straying off topic slightly.

Casper · 2016-12-06 21:16:18

This is why i say use a hosting site. Rotate on site and just like the image tag to your post. This is a free forum with limited or no adverts what is run from a wee man in his dark bedroom. I would rather just link pictures rather than upload filling up the wee mans storage allowance on the server.

Anyway, yer clean van.

Whats the plans, Single/double bed. Fixed cooker, 240v power, or stealth get away for the weekend for you and the dug?

Hywelius · 2016-12-07 23:03:39

Testing...

YEAHHAhaaah!!

(Google Photos)

Hywelius · 2016-12-07 23:18:18

Casper wrote:

Anyway, yer clean van.
Whats the plans, Single/double bed. Fixed cooker, 240v power, or stealth get away for the weekend for you and the dug?

I'm currently at a stage where I need to make some serious decisions about this really. At the moment, up until now I've been thinking of a full length folding bed blocking off the RH door with storage underneath - RH Door still usable, but ideally not with muddy feet etc. so need to get clever with some hinges and Tailgate lift gases i'm thinking to make a nice easy lifting cupboard under the sofa/bed!

As for the other side and facilities/amenities I'm thinking 2 ring hob, at the back near the rear door, undecided about a small sink yet (surface space might get more use), 3 way fridge, and as much storage as poss - maybe some hanging shelve units or something. they'll have to be on the left as the right hand ceiling space will be reserved for a surfboard or two hanging above the bed I think. I will be getting a roofrack at some point but its so much easier to chuck them in and forget about them than strap to a roof if it's just a small trip.

The fridge is the bulkiest thing so I'll probably need to get that and build around it. Just need to decide where to put it. I'm thinking of near the LH door and having access at the left still (but fridge blocking half way across, still plenty to nip in & out)

Something like this Fridge

And

'Ob

I've got some ply etc. left to build the bed with, and potentially the units. May also get round to finishing it off with some recycled 'pallet' wood cladding with a bit of wood stain or something.

A wood burner is a pipe dream but I think realistically it's only a small van and that is probably out of the question if I want it to still be functional. haha

Casper · 2016-12-08 01:06:27

Nah. Bin the wood burner idea. You could get a gas or diesel heater but i am yet to have a cold night. Saying that i am also yet to kip in the van in the winter months. Dont think i would be wanting all the bugs from the chopped wood in my van anyway big_smile Did you look at my blog? I stuck an awning on with sides. When it got chilly in the evening sticking the gas burner on was good enough to heat the awning and van. Fridge, Do you need one? i never felt i did and my next van wont be having one either. If i score one mega cheap or free i may but its not on the list. Buy milk when i need it if its beer you want then store that in the topbox. The wind chill keeps that cool enough big_smile

Wee half hour on a single burner heat this and the van up

Hywelius · 2016-12-08 01:33:41

Yeah I suppose with a couple of burners it wouldn't take long for the hob to do some work on heating the van (soon find out how good my insulation is). It definitely would be a a pure indulgence so I can sit and make fires. but maybe impractical. We do tend to go surfing all year round (sometimes waves can be better in winter), and when you're getting out of the North sea in January sitting by a fire seems like a great idea! A friend's got one in his van and it's mint. I rate it. But his High roof LWB van probs has the space for it - unlike mine.

I do want it to be a functional camper in all weathers too - as I'm hoping to take it on the continent at some point and get it in some hotter weather - where a fridge would be handy for my (yes beer) but mainly meat etc. - if i'm going 'off grid' ish with it then shops may be few and far between. Pure convenience and comfort really. I think I would get alot of use.

Roof box will probably be put on for longer trips yeah. haven't really looked at them yet at all. I'm thinking rack first.

I did check your blog out yeah! had a good look through! I think putting a separate radio off the leisure batt is a good idea! need to decide on where electrics are going before I go ahead with that though.

vaz2121 · 2016-12-08 15:23:02

I have friends with small wood burners in their vans, but they've got much bigger vans though and they swelter when they get wood burner going even in winter and most have said they wouldn't do it next time... one of those portable aerosol can gas heaters would do fine .... only time I feel I need a heater is winter mornings when getting up (hot water bottle helps if needs be through night), But really only to take the chill off... In the past when I was on the road all the time if I didn't have a fridge van on the back of the artic and even then most of the time they were sealed, I like Casper has said put milk ETC in air flow (in a basket strapped to cab roof or mostly under trailer) it does chill them and another thing we did was if we were away for two or three weeks was to strap a large as poss those plastic boxes with a lid to roof of cab behind air deflector on cab ... fill it about a third of the way up with water put in some soap powder and T-shits, socks ETC ... A days worth of clothes or so........... but leave at least half the box if poss free for it to slosh about and hey presto a washing machine (refilled afterwards helps keeps beer cans chilled as well)..... and after a rinse out, good enough for keeping going anyway........ Another thing we did was to have those Hospital type Pee bottles in-case we got caught out .........Space in a van our size, bed is priority but then I'm not going surfing .......... Go with Casper and think about an awning

......I saw an idea some where ... they put some garden hose pipe along inside behind paneling of van so they could slide wiring along if the had a need to fit something afterwards.....

Last edited by vaz2121 (2016-12-08 15:28:32)

Casper · 2016-12-08 16:48:40

Another idea to save space is a 12v coolbox. That can get chucked up the roof box when not in use. Measure the gap and what you are buying and it could sit between the seats after you get a single passenger one. Full size roof rack and also get the spare up there then you can get clever with all that underside space. My roof box is more than enough for clothing for two and the dogs food, coocking utensils all to be stored in for a two week jolly. There is still plenty room up there for a couple of surf boards sitting side on. You could even have two roof boxes.

monkeynut · 2016-12-09 00:02:25

I have a space between the gas bottle and plastic water tank, that keeps my beers cold and food fresh! I did the same in my VW T3 big_smile

Hywelius · 2016-12-10 16:22:41

vaz2121 wrote:

....they swelter when they get wood burner going even in winter ........
plastic boxes with a lid to roof of cab behind air deflector on cab ... fill it about a third of the way up with water put in some soap powder and T-shits, socks ETC ... A days worth of clothes or so........... but leave at least half the box if poss free for it to slosh about and hey presto a washing machine...

Sweltering sounds pretty good when I have the kind of circulation i do when my fingers are white and wet! But yeah in such a small space a smaller easier heater might do. Lazyness will probably prevail - starting a fire might be fun for a little while, but the enthusiasm won't last i'm sure smile probably will become a ballache!

I love the washing machine idea! I can see myself ragging the expert to get a proper slosh going!!

Still haven't bought any fridge yet - appreciating all the ideas and definitely taking them on board. But still undecided. the between the seats/gas bottle voids sound promising, but at the moment i'm still inclined to go for something like I posted earlier. hmmm

I'm getting a bit more insulation done today and got some lino flooring to go down 4m x 1.7m for £20 'end of roll' type thing, plenty! Watch this space - If I get enough done I might even get round to starting a bed this weekend - I've got the wood / hinges for it.

Just taken my cab roof lining off and discovered a big old patch of condensation hanging above the cab - very wet up there. Given it a good wipe down/dry off - hopefully a layer of some foam won't hold any of that when it's back on.

Hywelius · 2016-12-30 21:54:48

***EDIT*** Hopefully the pics are showing now?? ****

Merry Crimbo, Hope all had a good one! I did well on van stuff..tupperware and utensils mostly!...Update time...

This wheel arches could have been neater, I rushed them a bit - but whatever - it's going to be covered up:

Here's the condensation (and tiny amount of rust beginnings) I found in the cab roof after taking the lining out...

Bit of insulation for the roof lining...

A bit more help from the pets with the floor...Got a nice bit of lino offcut for around £20

Extra ceiling insulation layer...

Testing hammock length...it's a bit small for me to be comfortable in for a night etc. but will serve as a good chiller when parked up or something between roof bars/trees or another van or whatever:

Time to make a start on some furniture...Bed first...

Side storage access...

Contour cutting..

It'll need a few more hinges as the ply is a bit wobbly at each end. The plan is to have another piece that will 'roll' up on top of this. The base is solid as a rock though I added plenty of support, if anything, overkill but I thought it would be better for the longevity of it. It's anchored into the pillar and that metal box thing by the wheel arch. also into the floor at a few points.

It's coming together nicely! Hopefully will get chance to have a go at the rest over new year break.

Last edited by Hywelius (2017-01-08 01:07:49)

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#1 2016-12-03 23:43:38

Peugeot Expert 55 Plate - MY VANSION

#2 2016-12-04 00:00:02

Re: Peugeot Expert 55 Plate - MY VANSION

#3 2016-12-04 00:07:29

Re: Peugeot Expert 55 Plate - MY VANSION

#4 2016-12-04 00:35:18

Re: Peugeot Expert 55 Plate - MY VANSION

#5 2016-12-04 00:52:31

Re: Peugeot Expert 55 Plate - MY VANSION

#6 2016-12-04 01:03:05

Re: Peugeot Expert 55 Plate - MY VANSION

#7 2016-12-04 01:15:34

Re: Peugeot Expert 55 Plate - MY VANSION

#8 2016-12-04 01:20:09

Re: Peugeot Expert 55 Plate - MY VANSION

#9 2016-12-04 01:46:14

Re: Peugeot Expert 55 Plate - MY VANSION

#10 2016-12-04 01:53:47

Re: Peugeot Expert 55 Plate - MY VANSION

#11 2016-12-05 23:55:33

Re: Peugeot Expert 55 Plate - MY VANSION

#12 2016-12-06 00:41:25

Re: Peugeot Expert 55 Plate - MY VANSION

#13 2016-12-06 01:34:58

Re: Peugeot Expert 55 Plate - MY VANSION

#14 2016-12-06 13:07:19

Re: Peugeot Expert 55 Plate - MY VANSION

#15 2016-12-06 21:01:37

Re: Peugeot Expert 55 Plate - MY VANSION

#16 2016-12-06 21:16:18

Re: Peugeot Expert 55 Plate - MY VANSION

#17 2016-12-07 23:03:39

Re: Peugeot Expert 55 Plate - MY VANSION

#18 2016-12-07 23:18:18

Re: Peugeot Expert 55 Plate - MY VANSION

#19 2016-12-08 01:06:27

Re: Peugeot Expert 55 Plate - MY VANSION

#20 2016-12-08 01:33:41

Re: Peugeot Expert 55 Plate - MY VANSION

#21 2016-12-08 15:23:02

Re: Peugeot Expert 55 Plate - MY VANSION

#22 2016-12-08 16:48:40

Re: Peugeot Expert 55 Plate - MY VANSION

#23 2016-12-09 00:02:25

Re: Peugeot Expert 55 Plate - MY VANSION

#24 2016-12-10 16:22:41

Re: Peugeot Expert 55 Plate - MY VANSION

#25 2016-12-30 21:54:48

Re: Peugeot Expert 55 Plate - MY VANSION

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