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#26 2020-07-15 15:13:29

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

heh yeah. Asperger syndrome combined with dyspraxia and slight autism has it's benefits I guess..
I just don't want a vehicle that will fail on me In some way in the future. fix everything now and it will be cheaper in in both time and money in the future. I have another car i can use and am still on furlough. so fix it fix it fix it..

I have the aircon system vacuumed down and ready to take refrigerant. the Halfords "top up" bottles get around the UK law on charging a AC system but I am not sure how.


this is my latest video taken before i took the van out for a test drive. i am pretty happy with how its all gone together!


Last edited by JohnDragonMan (2020-07-30 00:41:47)


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

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#27 2020-07-18 02:47:10

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

so this.

mini_20200717_214008.jpeg
mini_20200717_214012.jpeg

i really need to lock the socket set away.

lincolnexpert on here has just done their rear axle bushes. so i though for what it takes, ill just completely take off the rear axle. its a rather easy job if you can get your brake pipes off. i hate "crimping" brake flexi hoses but i thought with me replacing them, like it matters. hand brake is a pain to disconnect as you have to undo the 10mm adjusting nut all the way off on the shorter cable to get it off.
Abs sensors are pretty easy.

just ordered myself some bushes, cant seems to get bushes for the anti sway(?) bar, the bar that sits above the rear axle.
my one is pretty rusted and the small bushes at each end are pretty rough.

heres why the axle came off. so i could get under i and clean before treating and painting

mini_20200717_214048.jpeg

mini_20200717_214226.jpeg

mini_20200717_214403.jpeg




theres a video on its way too!

Last edited by JohnDragonMan (2020-07-18 02:52:24)


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

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#28 2020-07-19 09:23:49

lincolnexpert
Member
From: Lincolnshire
Registered: 2020-03-09
Posts: 75

Re: JohnDragonMan's Dispatch Camper Conversion

Great Thread John. I would of had a breakdown at many points of this project. Going to enjoy following it to it's conclusion.
Man I wish I had your Skills!

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#29 2020-07-20 00:35:58

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

heh this is not skills. this is a combination of living as cheaply as possible and years of bad luck, knowing what will happen if i dont fix it now.

should see it now. the back end is now totally rust free. that means no surface rust or hidden rust.

got new brake hoses on the way. very tempted to change the shocks as its like riding a pogo stick over speed bumps. after taking the rear axle off and inspecting them it takes nothing to compress them (they move in under their own weight) and are slightly more difficult to pull out. yep pretty much at the end of their life.
can pick up a replacement "QH" branded pair from Ebay for £50... but i am tempted to push the boat out a little and get Sachs. of which there's 2 different hardness to choose from. some nice soft ones would help the old pots and pans in the cupboards but the stiff ones will give better handling..  hmm

i do have some old Fiat panda shocks which are the same length as the ones on this van.. for what they take to change, it would be interesting to have a play and swap them over to see how much difference they have.

ill take some photos tomorrow of the work i have done so far as i know you all like pictures.

sadly i have been called back into work. my virus holiday has come to an end and next monday (3rd) it will be back to setting the alarm for the old 9 to 5, battling traffic and heading of to my place of deconstruction. though more than likely i will spend the first few weeks welding all of the broken skips up and fixing broken machinery. hey at least ill be back up to full minimum wage rather this 20% off stuff it has been!

Last edited by JohnDragonMan (2020-07-20 00:37:26)


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

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#30 2020-07-20 10:40:49

lincolnexpert
Member
From: Lincolnshire
Registered: 2020-03-09
Posts: 75

Re: JohnDragonMan's Dispatch Camper Conversion

Looking forward to some more photos. Interesting re the panda shocks. I'd be tempted to go with the Sachs if you have the pennies.
I'm guessing going back to work will slow this project right down now. At least the Lockdown has been good for something. Loads of people have finally got round to starting/finishing projects smile

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#31 2020-07-22 01:33:42

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

alright. so heres the pictures of the rust protected finish.

all i can say is its not a very pleasant job chipping, wire brushing and filing away all of the rust.

so i pretty much got everywhere i could back to shiny metal. i then painted everything with a paint that has a built in rust converter and inhibitor (2x coats). i then went over the paint after a few days of drying with a thick brush on underseal. theres a few cavities in that area too that you can get the dynax tube in and give it a good internal coating. stop and prevent any bastard rust in its tracks.

mini_20200720_175456.jpeg

mini_20200720_175508.jpeg

mini_20200720_175527.jpeg

mini_20200720_175553.jpeg

mini_20200720_175638.jpeg



i have the rear axle kinda back in now. i spent most of today cleaning up the coil springs and those 2x bars that slot in above the rear axle. both really rusty. then just cleaning up other bits on the rear axle and painting. this job is 90% waiting for paint to dry and 10% doing the work.

while i was waiting for paint to dry i decided to wire in door pin switches on the rear doors for my newly fitted alarm. now my alarm knows if a back door has been opened. this is good for 2 reasons..  1, the obvious theft factor. 2, the alarm has an auto lock feature, so if you unlock the vehicle and never open a door it will auto lock the vehicle after a while. all well and good till you unlock the van, throw your keys in the back, the alarm does not know a door has been opened then locks the van via central locking.... then keys locked in back of van...  thankfully that will never happen now. phew.

thats all for now...


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

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#32 2020-07-25 00:47:31

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

so today in my local scrap yard a dispatch van came in... which had a full after market bulkhead in it. no curves all angles.

all well and good but my van was not on the road.. i still had it up on ramps, with all the brakes disconnected and all of the hand brake components hanging up from yesterdays de-rust and paint-a-thon that i was doing. so hit the ground running when i woke up this morning and checked my facebook to see my local scrappers had this van in.

yesterday i managed to wire brush and de-rust the whole length from wheel to wheel on the drivers side, then repaint rust patches with metal paint (with built in rust converter). it was all dry by this morning so i undersealed the lot then set to rebuilding the hand brake. when that was done i changed the rear brake flexi pipes then bled the brakes.. it was getting on for 3pm by this time and the scrap yard closed at 4pm so the test drive for the van was going to the scrap yard to get the bulkhead.. 

and it worked flawlessly.

it felt so good. great engine power, nice suspension, corners lovely. real nice.

mini_IMG-20200724-WA0001.jpeg

called into costco on the way back home. big_smile

its a shame the van i got the bulkhead was scrapped to be fair. it needed rust repairs but all seemed pretty easy work. just the outer sill needed cutting out and a new bit welding in. the van started and drove quite nice. brakes needed changing on the back as the handbrake was a bit strange maybe stuck adjusters. had the DW8 engine. sadly i dont think they would sell the whole van cheap though. for a car its a minimum of £500.

though i have had some absolute cracking cars from this scrap yard in the past:

https://www.fiatforum.com/members-motor … a-fun.html

https://www.fiatforum.com/members-motor … -mjet.html

still have the last one^^ big_smile

its impressive this scrap yard still lets me buy cars from them big_smile


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

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#33 2020-07-26 12:17:31

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

so this is the bulkhead. its pretty beefy! kinda a shame that i am going to cut it up a bit for what i have designed.. but oh well..

mini_20200725_162800.jpeg

so the plan is to make it so the drivers seat can fold flat, so i can get access from the back into the front by dropping the seat back should i need to (because i am too lazy to get out and walk around to the drivers door haha)

now i just need to get it in here.. hmm.

mini_20200725_162816.jpeg


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

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#34 2020-07-27 02:16:39

Casper
Member
From: East Lothian
Registered: 2015-12-20
Posts: 1,627

Re: JohnDragonMan's Dispatch Camper Conversion

I found bulkheads to be a tad shit. Being tall i could not get the seat back far enough so managed to get 50 quid for mine and hammered out the lower section to allow swivel plates for the seats.  Made a R n R bed for the back and found incorporating the front area made the van huge again.

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#35 2020-07-27 08:57:28

kenbw2
Member
From: Anywhere the van takes me
Registered: 2017-11-26
Posts: 597

Re: JohnDragonMan's Dispatch Camper Conversion

Same. I used to have front facing seats and it was painful - swivel seats make the front space useful and saves you from needing additional seats in the back


2000 Citroen Dispatch 1.9TD XUD9 Camper Conversion + full time home
1999 Citroen Dispatch 1.9D DW8 Disassembled Camper Conversion
1996 Peugeot 806 1.9TD XUD9 Spare vehicle
1998 Citroen Synergie 1.9TD XUD9 Snapped timing belt

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#36 2020-07-27 14:35:06

tee_cee
Member
Registered: 2016-03-18
Posts: 304

Re: JohnDragonMan's Dispatch Camper Conversion

Having removed the bulkhead in my 2015 Expert, I sometimes wonder if it may have been part of stuctural protection in the event of the van rolling on to its roof.

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#37 2020-07-27 16:18:45

Casper
Member
From: East Lothian
Registered: 2015-12-20
Posts: 1,627

Re: JohnDragonMan's Dispatch Camper Conversion

tee_cee wrote:

Having removed the bulkhead in my 2015 Expert, I sometimes wonder if it may have been part of stuctural protection in the event of the van rolling on to its roof.

Do you mean that lower section? I would like to think if it was structural it would have been welded in place rather than two bolts and a bead of some form of silicon

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#38 2020-07-27 17:15:47

tee_cee
Member
Registered: 2016-03-18
Posts: 304

Re: JohnDragonMan's Dispatch Camper Conversion

The upper section had beefy rivets. The lower section was welded to a seam in the floor in a couple of places for a couple of cm. Plus copious amounts of tough as nails sealant.

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#39 2020-07-27 20:50:36

OAT
Member
From: Borders/Dales
Registered: 2017-01-03
Posts: 537

Re: JohnDragonMan's Dispatch Camper Conversion

I doubt they would consider roll over protection to a van but not a people carrier. 
Any strength in the bulkhead is to stop the load hitting the back of your head.

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#40 2020-07-30 02:52:15

JohnDragonMan
Member
From: Derby, East Midlands, UK
Registered: 2020-06-02
Posts: 84
Website

Re: JohnDragonMan's Dispatch Camper Conversion

OAT wrote:

Any strength in the bulkhead is to stop the load hitting the back of your head.

This.

so i plan on installing some pretty heavy things to my van such as an inverter and a compressor fridge. all of this is going to be behind.. me. well in a crash i dont think the wood i am going to build the cupboards out of will stop said inverter and fridge from flying forwards and giving me a bit of a head ache. so i really want the bulkhead.

i also want it for security, and heat retention. the front of the van is pretty pointless to insulate in my eyes with it having so much glass. so i will insulate the bulkhead and that can be my thermal barrier.

my plan is a sliding door behind the drivers seat that i can slide across then drop the back of the seat to gain access into the front/back.
yep im a little nuts but hey, we already know that.

videos coming soon.. technical difficulties..

Last edited by JohnDragonMan (2020-07-30 02:56:10)


- JohnDragonMan
Notice: I have the tendency to void warranties, blow fuses, cause fires, and other fun stuff.
Words of wisdom: There's always user serviceable parts inside. Molten metal "hot". In my defence, i was left unsupervised. "Oh that shouldn't have happened".
My Crazy Mk2 2005 Dispatch Camper Project big_smile

Offline

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