Peugeot Expert WAV Conversion

Dolomite · 2016-02-14 11:02:57

Hi, thought I'd start this to keep a log of what I do - hopefully I'll keep on top of it as much as possible..

Just a quick note: I would like opinions advice and comments posting on here but if the subject matter becomes too removed from my conversion could a new topic be created for the discussion as I wouldn't like the thread to become too convoluted. Hope this is ok?

Wish me luck

Cheers!

Dolomite · 2016-02-14 11:22:33

So - found a guy near Barnsley with a wreck of an 806 who agreed to let me have the seats for £100 before he scrapped it (as long as I gave him my drivers side one to get it there!)- maybe I went in too high but as it turned out he more than earned it...

so not really knowing what I was doing, I tried to get my drivers side seat out and failed bleeding and cold! The seat came off the base fine but those bolts on the base where impossible (maybe my lack of experience is showing here?)

So having read on here how easy it should be (not yet actually re-reading Monkeynuts post!) I guessed that the bases were probably the same and the seats would bolt onto the slidey track things and anyway I wanted a pint.

Called the guy on the way over on Saturday just to let him know I had only the seat bit - turned out he hadn't been able to remove the bases either! fantastic, must be fine!

Anyway, as I'm sure is perfectly obvious to everyone else we checked the seat holes against each other and theyre out by around 10mm.

4 hours later having used a crowbar, chisel, big hammer and an angle grinder we finally got the bases out of his (relatively) unharmed, it was very good of him to put in all this effort with no complaints at all.

So now the important part: I have to repeat this with mine without damaging anything. I have a plan to wd40 the underneath of all the bolts even if it means removing the exhaust and going at them with a wire brush? Having already rounded some of the torqs off I'm seriously dreading it

Any tips from people who have done this?!

Casper · 2016-02-14 15:46:45

I was trying to get a seat out at the scrap yard and gave up due to the dam nuts getting stuck. Yeah i think its crud on the threads but the van i was at had no wheels so could not get under. It was the two larger nuts that was getting me stuck so let us know how you get on as i will be swapping my passenger seat over to a single swivel.

Dolomite · 2016-02-14 16:09:38

Will do, I've had quite a few offers of help since telling friends about the project, so I am half wondering about inviting them all round and setting them on with it while I cut up some plywood or something!

I'm was unsure if I wanted both of them to swivel, however, I thought I might as well just do it as they are comfier seats and having not actually decided on a final design it gives me flexibility...

Dolomite · 2016-02-27 20:36:43

Quick update - just managed to fit the swivel seats, this was nowhere near as bad as my last experience, the difference was a little proper planning and preparation! The passenger ones came off with no fuss at all. We put the van up on ramps gave the bolts a quick clean and left some plus gas on for 10 mins, they came straight out and I felt a fool for making such a big deal about it previously.

One that I had sheared the head off was a little troublesome, but I followed my dads advice and used a blowtorch to heat up the welded nut and from then on it turned no problem, just slow awkward progress to get it out. Also at one point I wondered how flammable wax oil is as it smoked a little....

As I said above, It's all experience and patience and following my main rule from when I had my classics: never start a job when there's a particular time your planning on going to the pub!

So as well as putting the new seats in I have stripped out all the wheelchair praphenalia, the ramp & amazing amount of straps etc. this leads me onto my happy discovery! I have good strong threaded bolt holes all over the place in this van - several perfectly placed to bolt my seat/bed and "kitchen" units to.

Having removed the ramp I am left with a useful(?) gate that swings down for easy entry from the rear! There is some rust on some of this as they were always converted aftermarket, to varying qualities I imagine. Mine is probably a bit of a slapdash one. My friend has suggested sand it off use b&q rust treatment, paint to protect. Has anyone got a better idea?

I think the next step will be ply and insulation where I can. But any advice appreciated

I will attach photos soon

Ta, Ben

Casper · 2016-02-27 21:35:17

Insulate everywhere you can

Here is one example.

http://www.fiatforum.com/members-motors … diary.html

Tiree · 2016-03-01 13:12:07

That's a great example Casper .. a good read.

Totally agree - insulate as much as possible. You'll thank yourself for it later!

One thing I'd say is try to use the recycled plastic loft insulation (rather than polystyrene sheet) for the second layer. It comes out like cotton wool so with some pointy, flexible implements, you can get this stuff into every crevice of the van.

tee_cee · 2016-03-18 15:54:28

My conversion was an Expert WAV also. I did a bit of a build log, mainly to remind myself what I did and where I sourced the bits.
The website is http://blue-van.blogspot.co.uk/ you might get a few ideas from it.

Casper · 2016-03-18 16:20:58

tee_cee wrote:

My conversion was an Expert WAV also. I did a bit of a build log, mainly to remind myself what I did and where I sourced the bits.
The website is http://blue-van.blogspot.co.uk/ you might get a few ideas from it.

I seem to remember glancing over that a while back and meant to look a lot closer and lost the link so thanks for sharing. I do remember thinking how much shit can someone pack into a van, were you moving house big_smile lol

Quick Edit.

Tee_Cee. How wide is your rock n roll bed. I am about to start making one and giving four foot but looking at yours its obviously thinner. Does it sleep two OK or a tight squeeze also did you keep the original single front passenger seat?

Last edited by Casper (2016-03-18 16:33:38)

Tiree · 2016-03-18 16:32:46

Yep I've spent a fair while browsing your story recently tee_cee!

Welcome and thanks for sharing!

Tempted by your sun shade ... did it all hold up ok?

Dolomite · 2016-03-18 16:38:37

Thanks a lot for the link to your WAV, I have seen that before too - do you have anymore photos of the build at different stages? it is a great use of space - what is the width of your bed?

tee_cee · 2016-03-18 17:12:23

Well we do pack a lot because we tend to go away for long periods. Last years trip lasted for 150 days.
The bed is 1.04m which is narrow. I'm 5'10" 75kg and the wife is about 5", and we have no problem with the space. In fact we can pretty much spend the night without touching each other - we have been married a long time. The key to this was fitting in the compressor fridge, which dictates the rest of the design. An alternative may be to fit a chest fridge underneath the seat - using the extra space where the wheelchair ramp was.
Here's a link to the bed frame page http://blue-van.blogspot.co.uk/2014/01/bed.html
I did put in 2 swivel seats - but in practice the passenger seat never gets turned around.

Dolomite, the build log was primarily for my own reference, so its not laid out in a user friendly way, but if you wanted pictures of some specific details I can do that. I did some more tweaks over the winter and intend to do some more photos shortly.

Tiree, yes the shade worked very well, especially when we had light rain - we could still cook and eat outside. The only change for this year is an upgrade to adjustable steel poles to help when the rain is heavy.

Casper · 2016-03-18 19:15:04

That Google blogspot you use. How do you get page two, three etc to show up on the right. I add a page and publish yet nothing shows up on the page one link. I have to add a page two url as the bottom of page one what looks tacky.

tee_cee · 2016-03-19 18:22:34

Casper wrote:

That Google blogspot you use. How do you get page two, three etc to show up on the right. I add a page and publish yet nothing shows up on the page one link. I have to add a page two url as the bottom of page one what looks tacky.

If you go to the blog design and click the layout button on the left, you can add a "pages" gadget to the sidebar.
Its probably more useful to create pages rather than posts.

Casper · 2016-03-19 18:58:49

tee_cee wrote:

Casper wrote:
That Google blogspot you use. How do you get page two, three etc to show up on the right. I add a page and publish yet nothing shows up on the page one link. I have to add a page two url as the bottom of page one what looks tacky.
If you go to the blog design and click the layout button on the left, you can add a "pages" gadget to the sidebar.
Its probably more useful to create pages rather than posts.

Sussed it mate but went one better with a floating menu on the sidebar smile

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

Dolomite · 2016-03-29 11:29:41

Hoping the photos work - first pictures of inside of van inc insulation

https://www.flickr.com/photos/benja_uk/ … posted-ff/

tee_cee · 2016-03-29 11:46:08

Looks good. Looking at the design, this looks exactly the same as my WAV - which was carried out by Constables mobility.
In my case the rear tailgate area was damp, so the wood at the back was starting to rot, so I ended up removing the whole floor, and putting new ply over the top. The ramp area underneath is used for storing the table at the front, and other bits and pieces at the the back via the tailgate.
btw I got £45 for the ramp on eBay

Dolomite · 2016-03-29 11:52:26

hi, yes it is a constables one! the wood is ok but the metal is starting to rust, pretty messy job imo.

I have considered pulling it all up but I'm not that bothered at the moment - I can always go back and sort it if I decide its worth it.

I'm leaving the floor as is to give a bit of extra height and storage under the bed. it will also act as a runner to help the pull out mechanism

tee_cee · 2016-03-29 12:23:23

Yes, the back of mine is rusting as well. I just scraped as much of the rust off as I could, filled in the holes, painted with some rust inhibitor and hammerite. I'll need to do the same again this year - so its a bit of a losing battle, but maybe it helps to slow the process a bit. When I lifted the ramp floor, I could see that water had been getting trapped and the metal floor was starting to rust.
In the end I had to put a floor down, due to the the fixing points on the bed being narrower than the ramp well.

monkeynut · 2016-03-29 17:39:47

Dolomite wrote:

So - found a guy near Barnsley with a wreck of an 806 who agreed to let me have the seats for £100 before he scrapped it (as long as I gave him my drivers side one to get it there!)- maybe I went in too high but as it turned out he more than earned it...
so not really knowing what I was doing, I tried to get my drivers side seat out and failed bleeding and cold! The seat came off the base fine but those bolts on the base where impossible (maybe my lack of experience is showing here?)
So having read on here how easy it should be (not yet actually re-reading Monkeynuts post!) I guessed that the bases were probably the same and the seats would bolt onto the slidey track things and anyway I wanted a pint.
Called the guy on the way over on Saturday just to let him know I had only the seat bit - turned out he hadn't been able to remove the bases either! fantastic, must be fine!
Anyway, as I'm sure is perfectly obvious to everyone else we checked the seat holes against each other and theyre out by around 10mm.
4 hours later having used a crowbar, chisel, big hammer and an angle grinder we finally got the bases out of his (relatively) unharmed, it was very good of him to put in all this effort with no complaints at all.
So now the important part: I have to repeat this with mine without damaging anything. I have a plan to wd40 the underneath of all the bolts even if it means removing the exhaust and going at them with a wire brush? Having already rounded some of the torqs off I'm seriously dreading it
Any tips from people who have done this?!

i had a striped torx as well but sorted that out with some very good vice type grips with flat jaws(dident spray the bolts first silly me) due to lack of room on a couple of bolts i used the smallest ratchet i had to get a perfect uprite fit, dont forget the two large torxs bolts as they are for the seat belts, might be worth making smaller plastic spacers(or removing them to lower the seat base some)

Dolomite · 2016-03-29 17:42:53

I think I do need to remove the spacers - is this advisable you reckon?

monkeynut · 2016-03-29 17:57:00

well im 6.2 and use the 806 spacers as they are half the size so the difference wont be all that different if i took them out anyways , but if your using the van ones witch are larger you will notice the difference if you removed them , my seats are on the lowest setting but it would be the same as a 806 as im using the small 806spacers,
i reckon they are just to cut down on vibration anyways
hope that makes sense neutral

Dolomite · 2016-04-03 09:10:18

Built my seat/bed!

Dolomite · 2016-04-03 09:11:21

Nearly anyway - need a few tweaks etc..

Casper · 2016-04-03 16:00:33

Dolomite wrote:

Nearly anyway - need a few tweaks etc..

You will need sideways support on that bed/seat. Not sure if your would is thick enough for these brackets but you could just use 2"x2" spars or the likes.

Mine

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#1 2016-02-14 11:02:57

Peugeot Expert WAV Conversion

#2 2016-02-14 11:22:33

Re: Peugeot Expert WAV Conversion

#3 2016-02-14 15:46:45

Re: Peugeot Expert WAV Conversion

#4 2016-02-14 16:09:38

Re: Peugeot Expert WAV Conversion

#5 2016-02-27 20:36:43

Re: Peugeot Expert WAV Conversion

#6 2016-02-27 21:35:17

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#7 2016-03-01 13:12:07

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#8 2016-03-18 15:54:28

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#9 2016-03-18 16:20:58

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#10 2016-03-18 16:32:46

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#11 2016-03-18 16:38:37

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#12 2016-03-18 17:12:23

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#13 2016-03-18 19:15:04

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#14 2016-03-19 18:22:34

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#15 2016-03-19 18:58:49

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#16 2016-03-29 11:29:41

Re: Peugeot Expert WAV Conversion

#17 2016-03-29 11:46:08

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#18 2016-03-29 11:52:26

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#19 2016-03-29 12:23:23

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#20 2016-03-29 17:39:47

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#21 2016-03-29 17:42:53

Re: Peugeot Expert WAV Conversion

#22 2016-03-29 17:57:00

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#23 2016-04-03 09:10:18

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#24 2016-04-03 09:11:21

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#25 2016-04-03 16:00:33

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