Peugeot Boxer camper conversion

[reliantscimitar]

Hi all

I have just started a Peugeot Boxer camper conversion.

She's a 2009 short wheel base, standard roof but still 2ft longer and a foot wider than a Vivaro.

Spent a day removing all the dodgy racking,electrics and about 30kg of sand/soil/concrete.Have also removed the ply floor as it was only 9mm ply and in poor condition.

Spent yesterday and today on her. The wiring is in for 4 led roof lights, the rear door and side door panels have been made and covered in lining carpet.

I have cut and trail fitted a new floor from 12mm ply and also trial fitted a central roof panel.

Cheers - mike

[reliantscimitar]

[reliantscimitar]

Hi all,

didn't get much done on the Boxer this weekend but have made a start this morning despite the awful weather.

I'm insulating the roof and sides of the van with a 35mm polyester material instead of rock wool.Its the first time
I have used this insulation. Its light weight and easy to use and doesn't leave you itching for days afterwards.
I'm hoping to get the roof and sides finished today so that I can finish running the electrics and do the ply lining tomorrow.

Cheers - mike

[reliantscimitar]

Had a couple of hours on the Boxer this afternoon.

There's a fatal floor with using polyester insulation, you can't put screws through it so had to revert to
rock wool for the lower panels.

Got the passenger side rear quarter finished. Its taking longer than usual as I am making templates as I go so that
I can rattle a few of these conversions out next year.

Cheers - mike

[reliantscimitar]

Hi all

have now finished making and fitting the nearside rear lining panels.I have not flush fitted them on this
van like I do on a Vivaro as the supporting metal work is not flat plus I kind of like the not flat effect once its covered
in lining carpet.

Have now started making and bonding in the panels to cover the larger holes as its not really good practice to tape
over the larger holes. Have got quite a few to do.

Hopefully I should be able to start with the lining carpet tomorrow.

Cheers - mike

[reliantscimitar]

Hi all

Have had another steady day on the Peugeot.

The new floor is now bonded and screwed down, the drivers side rear is now fully insulated and has been boarded.

I have fitted the roof panel and led lighting and made some trim bits for the front and rear. Its now in but was a pain as I fitted the roof panel and then lined it with carpet. I did it this way to make sure none of the fixings were visible.

I doubt I will get to much time on her for a few days as I have major work to do in my wifes car and the bathroom has to be re-fitted this weekend.

Cheers - mike

[mikeyp247]

Nice.

[reliantscimitar]

Hi all

got a few hours on the Boxer yesterday. Made the end panels for overhead cupboards and
carpet lined the passenger side rear and corner.

Hope the get the bottom and sides of the top rear cupboards finished today.

Cheers - mike

[reliantscimitar]

Hi all

have now got the front and bottom of the passenger top rear cupboard made and trial fitted and i'm happy with the
fit.

I may remake the front support panel as one of the fixing screws will be visible.

Hopefully I will get the panels finished and the door made later this afternoon so I can do a final fit tomorrow.

[reliantscimitar]

Managed to make up the doors for the unit and then had to knock as feeling lousy.

Hopefully I will be better tomorrow and get the cupboard finished for good.

Cheers - mike

[hopeso]

Looking forward to seeing more of this as it progresses and then the finished article.

[Alpina99]

Nice work
Some "home brews" can look poorly finished but this looks really professional
Interesting project, please keep the updates coming

[reliantscimitar]

Hi all

Have lost 10 days on this build due to a severe chest infection but slowly on the mend now.

I hope to get a few hours in this afternoon and finish one of the top cupboards as its not to cold today.

[reliantscimitar]

Hi all

finally got one of the top cupboards finished and mounted this morning.

Its been that cold that my knock in trim as shattering when I try to fit it. Its usaully really flexible and easy to use but
today its just impossible to bend without pre-heating it. Roll on next week and some milder weather.

Anyways, i'm fairly happy with the design and fit of the cupboard so it can come down and be templated. I also have to line the top of the cupboard.

Cheers - mike

[brachunky]

Bookmarked! I like that you have not gone mad with insulation as many folk do with these conversions because lets be honest, how many days a year does one really spend in freezing conditions in them! Did an ex lwb high roof project a few years back & learnt a lot going through the process, one being not to over engineer! We have a 06 Relay bus in the family which could become a day van at some point in time which is of course, very similar to yours so interested in how you get on!

[brachunky]

Here's a piccy of ours!

[reliantscimitar]

Hi Brachunky

she looks a tidy van.I don't go overboard on insulation as, as you say, not many folks sleep in them when its really cold.
The insulation is more to keep the van cool in the summer and it makes a huge difference to noise levels.

I got a couple of hours on the Boxer earlier.
The passenger rear cupboard roof lining is now fitted and the cupboard fitted for good. I also re-made the end panel as I wasn't happy that you could see
one of the mounting screws.
The drivers side rear cupboard is finished and I have trial fitted it. Just got the roof lining to make and then I can
fit it for good.Once new year is out of the way I should be back onto this full time as I have a potential customer
who wants to take it over to France for the skiing.
It may be getting a diesel fired blown air heating system fitted once we have agreed price and final spec.

Cheers - mike

[reliantscimitar]

Hi all

I made and fitted the ceiling panel for the o/s/r cupboard this morning which meant I could finally
fit the cupboard permanently.

Next job is to make and fit the trim panels for above the rear door.

Cheers - mike

[reliantscimitar]

Had a good morning and got the upper rear trim panel made and fitted.

I also found the catches for the rear doors loose, so that will be one of the many noises then.

The screws were all loose so I have adjusted the catches and thread locked the screws.

Got to give it a good tidy up this afternoon, got a new drivers mirror and new electric window switch to fit.

Hopefully I can trial fit the sliding rock and roll bed in the morning. Once that's done I can measure up for the lower units.

Got to sort out a swivel for the double seat today as well.

Cheers - mike

[andy-v]

looks factory fitted, great work fella.