Member Since: 06 Feb 2019
Location: Hampshire
Posts: 882
D3 camper conversion...
So after a trial sleepover in the D3 two weeks ago, I've decided to plod along with my conversion of my D3 into a camper / overnight van. It'll still have four seats (me, wife plus two kids) but at the same time it'll have a fully functioning kitchen, single bed, plenty of storage, a composting loo, a dual battery setup and a diesel fuel heater for the cold nights.
This is what i planned it to look like but I've since decided to lose two of the middle row seats so it gives me room to hide the WC under a kitchen worktop, at the same time providing a worktop (it'll be at the window height) on which to prepare food when it's raining outside.
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Today's modest progress, firstly making a plywood template of roughly where the cupboards (boot area) and kitchen (middle row door area) will go:
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Then removing the surplus two seats in the middle row:
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I'm pleased with how much room there is. I'll comfortably be able to sit on the remaining middle row seat and swivel into the centre of the car, to have plenty of room to relax and get changed etc.
Next up (next weekend?) is to batten out the floor and put down a 25mm plywood base. I'll either carpet it or put down lino, I'm not sure yet.2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)
Member Since: 24 Sep 2023
Location: Highlands
Posts: 268
Good to hear that you have made a start and I look forward to the updates!
I'm not sure if you have viewed the various build threads on the Expedition Portal site https://forum.expeditionportal.com, but if not, it is well worth a scan and might give you some ideas. Mainly US-based, but a lot of the concepts and materials are valid!Previously:
2010 FL2 TD4e GS
‘93 Defender 110 200TDi CSW - still got this, non-runner on SORN.
‘87 Defender 90 4 cyl Petrol
‘83 110 CSW V8 - best ever!
Range Rover 2-door V8 (not sure of year - 4-speed box and vacuum diff switch)
Series III SWB Diesel
11th Dec 2023 7:38 am
riverblanche
Member Since: 31 Aug 2010
Location: retford'ish
Posts: 2210
Hi,
good luck with the conversion
I have managed a couple of sleeps in the D3 but its headroom that made it a 1 night/year
I have recently started a van conversion and the progress has slowed down
mainly as I keep getting other ideas from place and my "fixed" plan keeps changing
so thanks Worms that will be another delay while I look at that site and change my plans again
Member Since: 04 Sep 2009
Location: Almunge
Posts: 137
Very interested in this project as it's very similar to my plans for when all stars align and there is an opportunity to commence building.Defender 110 SE 2021, Tasman Blue
Discovery 1 V8 ES 1997, Epsom green
Discovery 3 V8 HSE 2006, Bonatti Grey
Range Rover V8 1983, Sierra Silver
11th Dec 2023 5:15 pm
NewDevon4rmy
Member Since: 14 Apr 2023
Location: in your rear view mirror
Posts: 18
Best of luck!
Watching with interest 👍🏽Current: D4 TDV HSE
Recently: CR-V Gen 2
Formerly: LR3 V8 HSE
13th Dec 2023 10:44 pm
Garwood56
Member Since: 24 Jun 2021
Location: West Sussex
Posts: 418
This is exactly what I have been thinking about for some weekend trips to North Wales and Scotland next year. Will be following with great interest.
15th Dec 2023 11:21 pm
DIY Ace
Member Since: 06 Feb 2019
Location: Hampshire
Posts: 882
Whilst my little ones had some friends over for playtime I managed to sneak outside for a couple of hours this morning. Have got down the frame for the floor, fits really well and secures into the original securing holes for the seats. Used some 44mm x 44mm planed wood and M10 bolts, made a simple formwork and fixed it down.
Next up, make a cardboard template for the floor. Maybe boxing day if the kids allow it!
Click image to enlarge
2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)
Member Since: 24 Jun 2021
Location: West Sussex
Posts: 418
Nice one and very neat. 👍 I’m going to be making a similar start middle of Jan so look forward to updates. Merry Christmas.
23rd Dec 2023 6:40 pm
Pimpintgepidge
Member Since: 17 Sep 2019
Location: Glossop
Posts: 123
Would it be worth adding something between the timber and metal body, maybe carpet or rubber to stop squeaking. I don’t mean to be nosey just iv done a few camper vans and always done the shelving in my work vans and timber on metal noises ain’t nice especially if you have to strip it back out to find it. Nice job though 👍2015 D4 HSE Loire Blue
24th Dec 2023 4:44 pm
highlands
Member Since: 11 Jan 2010
Location: NW Highlands
Posts: 5095
I'd be tempted to use some of the underbonnet insulated rubber material across the area and possibly 25mm kingspan/celotex between the timbers.Black 05 TDV6 HSE Auto
Grey 05 TDV6 HSE Auto (Gone)
54 TDV6 SE Man (killed by me )
24th Dec 2023 4:56 pm
DIY Ace
Member Since: 06 Feb 2019
Location: Hampshire
Posts: 882
Thanks, that's a really good idea. I'll stick down a thin bit of the removed carpet under the timber to stop squeaks.
I plan on putting down a load of insulation, maybe natural sheep's wool, to aid insulation both noise and heat. I'll leave it neatly cut into those gaps, not compressed so that I keep the air pockets in it, before I put down the ply floor.
I can't decide on what to put down on top - carpet, decorative lino, rubber or possibly just go with a type of phenolic plywood. Ideas?2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)
Member Since: 29 Apr 2008
Location: London
Posts: 516
Sheep's wool without fire retardants or any other additives sounds great.
Not keen on Celotex and the like myself because although they provide better insulation they emit formaldehyde and that's not great in a confined space.
John
24th Dec 2023 9:18 pm
gstuart
Member Since: 21 Oct 2016
Location: kent
Posts: 13657
DIY Ace wrote:
Whilst my little ones had some friends over for playtime I managed to sneak outside for a couple of hours this morning. Have got down the frame for the floor, fits really well and secures into the original securing holes for the seats. Used some 44mm x 44mm planed wood and M10 bolts, made a simple formwork and fixed it down.
Next up, make a cardboard template for the floor. Maybe boxing day if the kids allow it!
Click image to enlarge
May I also add that ur doing a fantastic job there , following with great interest, Also subscribed ,
Many thks for sharing
24th Dec 2023 10:12 pm
DIY Ace
Member Since: 06 Feb 2019
Location: Hampshire
Posts: 882
Getting on with the floor, I've made a cardboard template out of the box my new bike came in, then transferred it onto 18mm hardwood ply. Fits a dream, perfectly cut around the door mouldings and neat up against the one remaining middle row seat when both upright and in closed up position.
I've bought some recycled plastic insulation to put down, that's a job for next weekend before I screw down the ply and think about building the frame for the kitchen unit.
What do you reckon I should do with the floor - carpet, lino or something else? I'm erring towards a black auto carpet, to match existing, as it's both hard-wearing and warm under foot.
Click image to enlarge
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2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)
Member Since: 06 Feb 2019
Location: Hampshire
Posts: 882
Small update today, put down some recycled plastic insulation. Should be moisture and mould proof. It's a b!tch to cut with scissors but got there in the end.
Hopefully tomorrow I'll get to lay the ply floor and then carpet over it.
Click image to enlarge
2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)
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that will be another delay while I look at that site and change my plans again
) 
