Transit Custom EMTB Camper van conversion


Nickolp1974

Active member
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Jul 30, 2019
129
118
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Merida e120
So just after the 1st lockdown i decided to buy my self a van to convert. I did have an estate car but did not want to leave my emtb on the back even locked up. Often go to the lakes etc for long weekends hiking in the mountains but i've never taken my bike which influenced my decision to get a van. Ended up with a 65 plate high roof long wheelbase which is perfect as i can still park it in a standard car park space. I considered a sprinter or crafter but there just to big for my needs. Although space is limited especially with the bed down it all works and i have everything that i need and more. I've only used it 3 times this far due to being flat out at work and now of course another lockdown!! but those 3 times were great in sussing a few things out, what we still need and what we dont.

specs
2x 180ah batteries
1000w pure sine wave converter
aili battery monitor
240v hookup
12v power
USB's
5KW diesel heater (overkill)
swivel for passenger double seat
rock n roll bed with futon matress and memory foam
electric coolbox which chills 18c below ambient
toilet
combined sink hob with tap
external waste water
internal lights
roof vent
awning
12v jet wash for bikes
Awning
Table and chairs etc etc

The van originally was just a normal panel van with no windows etc, so it all got stripped out cleaned, bulkhead removed windows and rooflight installed. then onto sound proofing which took ages along with the insulating and i used products from Dodomat Dodo Mat Automotive Sound Proofing and Insulation the noise levels inside the van are superb, even with the wind howling and rain i can hardly here a thing and the van needs minimal heating to keep warm, oh the van walls are covered in lining carpet and altro flooring on the erm..... floor! No idea why i went for a 5kw heater, not actually used it out in the field yet but im guessing it wont be on for long. Overall the conversion took me about 6 weeks of weekends and nights after work which aint to bad cos i've had to learn everything along the way.

So i sized the batteries so it would charge 2 e bike batteries off grid but thats rated at 180w for 4 hours but the watts drop while charging so it may do 3 full charges while also supplying power to the rest of the van.

Oh and the bike securing was done with 19/15id tube with 15mm pipe clips and a block of wood for the front and tie down straps for the back wheel and the bikes are rock solid in transit, stems have to be loosened to get handle bars in but that takes all of 2 minutes to sort.

I could go on forever about it but i wont bore you!!! i just cant wait to use it fully and get away more often.

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Last edited:

Nickolp1974

Active member
Subscriber
Jul 30, 2019
129
118
Louth lincs
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Merida e120
Thats fantastic ..well done !
( I'm extremely jealous not only of the finished van ..but your skills in building it too)
Hope you have lots of fantastic adventures ..
Thanks, i enjoyed building it and learned alot. still doing bits as i go, dropped the fuel tank today to put an auxiliary fuel line in for the heater, really dont like working under vehicles but got there in the end.

oh if anyone has any tips to get rid of the carpet spray adhesive residue, shoots everywhere that stuff!! would be most appreciated
 

Trig

New Member
Sep 23, 2020
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Scotland
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Cube Hybrid Reaction
I stuck the bubblewrap foil insulation to the roof of my custom with it... can confirm it gets everywhere. And if you look up at the right moment, it even gets in your eyes!

It looks great. Would love to do similar, but got to keep it fairly empty for work use. Just got a camping bed and a table built into my shelfs.

Did you insulate behind the carpet or just carpet straight on the van?
I may steal that bike stand idea also... or be inspired by it rather :)
 

Nickolp1974

Active member
Subscriber
Jul 30, 2019
129
118
Louth lincs
Ride
Merida e120
I stuck the bubblewrap foil insulation to the roof of my custom with it... can confirm it gets everywhere. And if you look up at the right moment, it even gets in your eyes!

It looks great. Would love to do similar, but got to keep it fairly empty for work use. Just got a camping bed and a table built into my shelfs.

Did you insulate behind the carpet or just carpet straight on the van?
I may steal that bike stand idea also... or be inspired by it rather :)
Thanks, everything is sound deadened(deadmat hex) and insulated. Ceiling, floor and rear is insulated using dodomat superliner 12mm sticky back stuff and the doors and sides also use dodomat thermo fleece and then ply lined over the top before carpeting.
the stand thing works well, there fixed in place with just screws and washers underneath, i may slot them though to adjust for different bike lengths.
 

Trig

New Member
Sep 23, 2020
64
28
Scotland
Ride
Cube Hybrid Reaction
Ah i didnt notice the black stuff, thought you had used the foil bubblewrap thats on your wheel arches.I used similar stuff, supposed to be equivalent to a certain thickness of glasswool or pir board, but ive not been away since last september when i fitted it, so not sure if its made much difference.

Can get pretty cold in them without it though, i know that much...
 
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Nickolp1974

Active member
Subscriber
Jul 30, 2019
129
118
Louth lincs
Ride
Merida e120
for anyone interested, i used the van batteries to charge my ebike batteries. 2 shimano 8010 504wh batteries were used.
charge states % left
2%
14%
45%
48%
this was after 2 rides using both batteries and charged up on the same van charge 127Ah was used. For this test i used the newer and slower shimano charger.
Happy with this as that means 5 full bike charges(2 already charged) off grid and still leaves enough juice in the van for everything else that requires power. should be good for a nice 3 day adventure, well 2.5. If only this lockdown would lift!!!

Also got heater finished last week while isolating, had to drop fuel tank etc. kicks out some serious heat, should be nice and toasty in the midst of winter :D

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