Customer Hand Over

Upholstered by CarevanApologies for the lack entries for almost a month but Christmas, New Year took account of two weeks of it. I haven’t been idle though in the first part of January. With the van now having a full MOT the owners could insure and tax it so they could take it to Careavan in Rubery (Birmingham) for upholstery. I have to say the folks at Careavan did a first class and sensitive job and have matched the fabric to the colour scheme well. It now looks and feels really homely and cosy inside. Some people don’t like the carpet lining on walls but it does give a lovely snug and warm feel to a relatively small van interior.

Since it came back from Careavan I have fitted the kitchen unit, connected the gas system and pressure tested it(all tests passed first time I’m pleased to say), hooked up all the fresh and waste water plumbing and have now connected the electrics, both 12V and 230V systems. Full working order on the mains side of things but a problem with the Truma E2400 heater to sort plus a couple of LED lights aren’t working but otherwise its all looking great. These faults turned out to be really minor (pleased to say), one unconnected wire was the cause of the non working LEDs and the heater was simply a blown fuse on the PCB so all is now working as it should.

Extension lift ups have been mounted on either end of the kitchen unit to give some workspace and where the kitchen overlaps the side door I’ve fitted an access door to the rear giving access to the gas taps and perhaps allowing easier loading of shopping into the kitchen storage.

The two main ceiling lights are dual switched as well as having individual switches on the units themselves, this allows them to be switched on or off from two different positions. There are also LED strip lights above the side door and over the rear of the cab, these are both operated from a single switch just inside the side door. Other LED strips are fitted under the front edges of the high level cupboards, individually switched for ambient lighting. A separate DAB/FM/USB radio/Media player, powered from the leisure batteries, is mounted in the Sargent EC450 power control and distribution unit which is switched on or off via its own switch on the lower edge of the Sargent unit, the speakers from this radio are above the offside rear seat and TV area. We opted for this setup to avoid messing about with the in dash unit which is engine battery powered and CANBUS controlled. On the roof is a Snipe automatic satellite dish whose output is fed to a socket on the wall above the fridge, the Avtex LED TV includes a free to air HD satellite receiver so no additional boxes are required.

Two leisure batteries of 90 AH capacity are fitted on the floor behind the driver’s seat and the mains charger is hidden behind a closing panel at the side. Alternator charging and solar charging are dealt with by a CTEK D250S Dual charge controller, a clever piece of kit incorporating a MPPT solar regulator and intelligent, multi stage battery to battery charger. The solar charge is automatically split between leisure and engine batteries according to their need.

Lining and Kitchen Cupboards finishedIn this final week of January I have built the high level cupboard over the kitchen and fitted a work light there. Final bits of carpet lining fitted and the leisure batteries and inverter mounted and boxed. Full testing of all systems has now been carried out and the water system fully commissioned with just a couple of easily resolved minor leaks.

One issue that looked like it might give us problems was the fuel gauge, despite fitting a nice shiny new tank unit the gauge stuck resolutely to zero. A diagnostic scan showed the BSI unit to be reading the tank unit and the gauge to be functioning but they just wouldn’t talk to each other. The BSI unit was removed and sent off for testing and repair but after a week was returned untested as the company don’t have the facilities for such a new unit. Oh well lets plug it all back in anyway because without it the vehicle is dead…………….guess what, the fuel gauge now works perfectly!

And finally today the owners have collected their new motorhome. For the first night out we’ve booked them into the Severn Gorge site near to our workshop so that we are close to hand should anything major crop up. There are still the graphics to apply but we’ve agreed with the owners to wait till the weather warms up a bit for that.

MOT & Utilities

The local Citroen main agent only lists one seatbelt for this model and yes its not the one we need! although I don’t generally use pre owned parts on customers vehicles we had limited options available in this case. A quick search of ebay and the part was in my hand a couple days later, we now have a full MOT so mechanically sound and road legal.

Most of the last week has been spent making the high level cupboards for the nearside lounge area (rearwards of the sliding door), fitting the water tank, water pump, shower tray, toilet, shower, sink and vanity cabinet in the washroom along with all the associated plumbing. The toilet uses water from the main tank to flush so just needs a power supply for the flush valve. The washroom is lined with 2.5mm thick UPVC sheet sealed at the corner joints with Sikaflex to create a waterproof room.

shower and toilet fitted in citreon relay campervan

Cupboards and Mechanics

Other work has taken precedence in the workshop so few hours have been spent on the conversion but I have managed to get the fridge into position and started building the high level cupboards.  Billy had used a lot of stuff from a retired late model caravan including cupboard doors so I’ve utilised them.  The high level doors are top hung on spring loaded hinges so no catches are required to keep them closed.  Cupboard base is 9mm ply with a 25mmX25mm Tee aluminium bar along the front edge, this adds stiffness and provides a flange below to carry the LED strip lighting.  The cupboards are also divided with 9mm ply mounted to the roof and base with 25mm angle aluminium for strength and lightness then the whole thing is Veltrim lined.

As we are aiming to deliver this conversion very soon I took the opportunity to service it before it went for MOT.  This was the first time I’d really looked at the mechanicals of this van and it proved to be not a pretty sight.  The cooling system header tank had oil in it, the brake pads were all crumbling, all four brake callipers had partially seized slides and half of the exhaust heat shield was missing.  I believe the cooling system oil content was simply a leftover from a damaged heat exchanger so a drain flush and refill was in order along with the same for the braking system hydraulics due to moisture content.  Then it failed the MOT! Not on much I hasten to add, poor windscreen wiper performance needing only two new blades, a broken wire causing intermittent operation of the number plate lamps and a passenger seat belt that wouldn’t latch into its receptacle.  Turns out there are a couple of slightly different designs for the seat belt buckle and we had a non matching set on the passenger seat.  As the belt itself has some slight fraying we’re replacing it completely.Citreon Relay Camprvan Conversion Interior Cupboards Citreon Relay Camprvan Conversion Interior Cupboards

Seating and Heating

Campervan Conversion

The Citreon Relay campervan conversion has been progressing steadily although I’m a little slow at updating the blog.  We now have the ceiling in place opting to use the ceiling panels that Billy had previously fitted, no point throwing out good material and it was already cut to size.  The van walls are now ply lined and most of the electrics are in place.

ply lined walls campervan conversion
The Walls are all ply lined and clad with Veltrim silver finishing carpet.

To finish the floor we have used a wood effect vinyl floor covering glued down, messy job but it gives a spill safe floor covering.

the rebuilt rear seats campervan conversion
We rebuilt the rear seating area including the raised floor in between but this time it is only raised in between the seats.

We rebuilt the rear seating area including the raised floor in between but this time it is only raised in between the seats.  The heating system comprises a Truma E2400 blown air unit mounted under the offside rear seat and will have four outlets: one in the rearmost part of this seat base, one into the washroom, one in the front centre of the raised floor and one at the front of the kitchen unit.  To accommodate the ducting the front 100mm of the raised floor will have a fixed panel but the remainder has been divided into six storage compartments with a removable top panel, this panel then forms the infill for the bed, its made from 12mm thick cherry veneered ply with strengthening battens glued and biscuit jointed to the underside.

Ceiling of the campervan conversion
We opted to use the ceiling panels previously fitted, it was cut to size and there is no need to waste good material.

The nearside seat base houses the Truma Ultrastore water heater and will house the fresh water tank and water pump.  Because Billy had originally raised the entire rear floor level the Ultrastore required a 100mm high raised plinth to support it so a simple and lightweight support was made from 9mm lightweight ply and covered with floor vinyl for protection.  As the Ultrastore is not new we gave it a full strip down overhaul first and the same will be done for the E2400.

rebuilt overcab campervan conversion
The overcab area has been rebuilt and clad with Veltrim Silver finishing carpet.

The overcab area has been rebuilt with a new plywood base and the whole thing is now clad with “Veltrim” finishing carpet in silver.  The ceiling has also been clad with the same Veltrim.  Ceiling lights consisting of two round units which will be double switched (one by the sliding door and one at the rear near the head of the bed), these will have LED bulbs fitted.

We plan to keep the citreon relay campervan conversion blog up to date with the progress we make. Check back regularly or follow us on facebook for updates. Dave Newell LVS Facebook Page

Vehicle Arrival

Citreon Relay Campervan Conversion – Vehicle Arrival

Since I started Dave Newell Leisure Vehicle Services (LVS) I have avoided taking on conversions of vans into campers on numerous occasions, simply because with only myself on the ground and my wife Jackie in the office and with conversions involving such a massive amount of work I always felt it was not viable.

This has all changed recently though, for a few years I have been thinking an extra man on the ground would be helpful but was always held back from advertising a position by not being sure I could bring in enough work to keep two of us busy full time.

So what changed you might ask?

A couple of good friends and customers opted to downsize to a panel van conversion (PVC) and were having one converted to their specification, sadly the company doing the work went into liquidation part way through. Our friends asked if we could store their van short term while they found another company to complete the conversion, we agreed. At about this time we let it be known through some of our local business contacts that we wanted a mechanic to join us and in less than 24 hours one walked in the door, long story short we took him on. Extra staff on the ground frees me up from the day to day stuff so we offered to complete the camper conversion for our friends. The final piece of the jigsaw clicked into place when the neighbouring workshop (Unit R, where I started the business 9 years ago) became available so we grabbed it to use for the conversion work.

citreon relay campervan conversion
Our Customers 2011 Citreon Relay – In for conversion into a campervan

The van in question is a 2011 Citroen Relay long wheel base in silver. The previous converter had done a fair bit of work to it including a new plywood floor, rear storage area accessed from the rear doors and incorporating a wardrobe in the centre interior face. Two inward facing seats form the living area at the rear, with Truma Ultrastore water heater under the nearside and Truma E2400 blown air heater under the offside. Nearside has the kitchen unit immediately in front and partially overlapping the sliding side door with fridge opposite. Immediately forward of the fridge on the offside is the wash-room. A Sargent EC460 provides the 12 volt and 230 volt fusing/circuit breakers and distribution.

Incredibly when the van was delivered to us it had no door mirrors, no cab seats, no cab seat bases, a totally dead engine battery (0.8 volts) and numerous dents and paint scrapes along with a split in the nearside rear door skin and a large crack in the windscreen. Even more amazing was the delivery method: the van was delivered on a recovery A frame and towed behind a BMW X5, as the recovery frame doesn’t provide brake function on the towed vehicle the delivery driver had a “mate” sitting on a wooden stool in the van, they didn’t even fit a towing board at the rear!

So we took stock for a day or two to establish (A)what we had to work with and (B)what exactly needed doing, the answers were (A) not a lot and (B) an awful lot! As the original converter (lets call him Billy (as in Billy the Kid, a proper cowboy) hadn’t cut any window apertures that was obviously pretty high on the list of jobs, while the wash-room was in place there was nothing inside it, no loo, no shower, not even a roof-light. The rear seating area was built on a raised floor section to put the top of the backrest cushions in line with the bottom of the windows. But he put the raised floor across the whole rear section instead of just the centre section between the seats, this wastes an awful lot of space as well as adding a lot of weight, especially when you use decking timber for support!

The owner organised some new cab seats complete with swivel mounts and bases but they came without seat belt receptacles so these had to be sourced seperately, at least we could fit the driver’s seat and move the vehicle about, door mirrors also had to be sourced and fitted. Billy was supposed to have fitted a bulk underfloor gas tank, an electric step and solar panel but seemed to have side stepped those three items so another couple of jobs got added to our list.

Apertures cut in citreon relay campervan conversion
First Job was to cut all the apertures in the body work for vents, windows etc.

Our first major task was to cut all apertures in the bodywork, these included windows in the side loading door and one each side in the rear seating area, a rooflight for the washroom to add natural light and ventilation and the toilet cassette access door. After that we moved it to a local bodyshop (Court Autos, Tweedale North, Telford 01952 581189) to have all the body damage sorted out, this included respraying the front grille surround, several body panels as well as removing several dents and weld repairs to the rear doors and respraying both. As expected Dave and his team did a first class job, we also got them to paint the hookup inlet cover, toilet cassette door frame and awning to match the rest of the van.

Two weeks later we had the van back and could start on the conversion proper….well so we thought. I noticed that the plywood floor had a spongy section near where the fridge would live so decided to lift the plywood and inspect. Turns out Billy didn’t bother removing the original plywood floor from when it was a delivery van and some sections were rotten, probably due to pressure washing. On lifting the original plywood floor we were gobsmacked to find a badly dented steel floor with broken spot welds in places but the worst was the ½ inch layer of what appeared to be congealed animal fat.

Floor of citreon relay campervan conversion
Previous Installers Plywood fllor stripped out and then cleaned and primed.

Two full days later we had it cleaned and degreased, repaired/straightened, primed, painted and a coat of stonechip to give some protection. On top of this we laid insulation, then battens then more insulation topped off with the plywood floor. The cab roof lining was filthy so we removed it for deep cleaning, this gave good access to the overcab area for insulation.

Electrics came next as they need to be installed before the insulation and furniture. Billy had a Sargent distribution unit from a caravan and its respective wiring looms so a couple of days went into sorting out the wiring and routing it in trunking and conduits to the relative positions. The mains wiring includes dedicated circuits for the separate water and space heaters, as the space heater doesn’t have an electric option we will wire that to a standard socket for a stand-alone heater.

spray foam insulation citreon relay campervan conversion
Cabin dash masked off for spray foam insulation
Back Wardrobe masked off citreon relay campervan conversion
Back Wardrobe masked off for spray foam insulation

For insulating the main body we opted for spray polyurethane foam. This is a two part liquid chemical product that comes in two steel cylinders. Hoses connect the cylinders to a gun with a clever mixing nozzle from where it sprays out as an off white sticky goo which adheres to almost anything and sets in 30 seconds to form a waterproof layer with a high thermal insulation rating, it also damps noise quite well so we expect this to be a really quiet van on the road. Spray foam is a very messy product to install but well worth the cost and effort, just make sure to protect anything you don’t want it to get on. Once fully cured any excess material can be simply cut away with a sharp blade, a flexible kitchen knife with a 12 inch blade works brilliantly. The cab roof lining could now be refitted along with a built in shelf for table storage, the edge of this area is padded with poly foam tube to protect heads from damage when moving into the cab. The overcab area is boarded out and carpet lined for a nice warm finish.

So with the wiring in, bodywork sorted, body insulated we decided to finish the cab with the final installation of the seats, bases, swivels and seat belt receptacles (this would then enable us to extinguish the airbag warning light on the dash as no seat belt receivers meant no pre-tensioners connected to the wiring). This was where we discovered the next batch of problems. The seat belt receivers were fine but had arrived minus their wiring harnesses, no problem the supplier sent them as a separate package. Problem was the passenger seat harness was wrong. We also discovered during deep cleaning of the cab that the fuel tank unit wasn’t secured in the tank but it wasn’t connected electrically either (could be why the fuel gauge is stuck on empty thinks I) so we plugged it in only to find the fuel pump sounded like it was gargling gravel! One new tank unit later along with a new passenger seatbelt wiring harness and all is now well in the world….well until the next issue pops up.

To complete tidying up of the silly little jobs that could so easily come back to haunt us if left we turned our attention to the rear end. The rear doors only give access to the rear storage area which Billy had made a passable job of so we left it be, well except for the carpet covering the lower sill. He’d glued it down over the sill and under the rear plastic bumper cover, just perfect to wick water up into the storage area, he’d also removed the lower rear door latch plate. We cut away the carpet lining from the sill, repainted it and clad the top surface with UPVC cladding sealed with a nice bead of Sikaflex. The rear doors are insulated with the same spray foam and finished off with the original lower door cards on the bottom half and varnished hardboard on the upper parts.

Rear doors insulated with spray foam citreon relay campervan conversion
Rear doors insulated with spray foam. Excess will be cut back.

We plan to keep the citreon relay campervan conversion blog up to date with the progress we make. Check back regularly or follow us on facebook for updates. Dave Newell LVS Facebook Page