Between Dreams

My first idea was to convert an Iveco panel van. I found one, opened the back doors and started to measure up. Yes, it could be converted but boy it was a small space, cramped with all the cupboards and beds in it. Having caravanned for years one of the main ‘must haves' was a fixed bed. At about this time my girlfriend, Lorraine  started to take more than a parting interest in what I kept going on and on and on about, and without her practical suggestions and encouragement, the truck may have never been built, because believe me there are some very low times during the build! So the project moved from being an ‘I' project to a ‘we' project!

Given the bespoke nature of what was taking shape in our minds, we spoke to a local horse box manufacturer, to see if he could make something? Of course he could -God bless Barry! He had many ideas, some of which we used later but for now he didn't really grasp what we wanted but he was happy to help us fulfil our dream. We even made a cardboard model of what we thought we originally wanted but as it transpired we didn't know at this stage either!

We decided to do more research on the internet, and on the self build motorhome site was a ‘Unimog' converted by Stephen Stewart (more about Steve later) and he recommended a book called Travel Vans by John Speed. In this book is a photograph of a truck build by Action Mobile from Austria. I fell in love with this truck. It was just what I was looking for. At long last I had found something that would be rugged enough to travel anywhere and still be in a reasonable amount of comfort.

The next challenge was how to get one of these trucks, as we didn't have the kind of money (there's no escaping it, is there?) to buy one off the shelf, so to speak, but willpower and motivation can overcome most obstacles.

I searched and searched the internet, printing off pages and pages of relevant information.  Stephen's knowledge was invaluable in this part of the process; he has some wonderful ideas in his document ‘Choosing an Overland Campervan'.

I had found web site's for Unicat, Ormocar, Fuss, Bimobile and TerraCross - all German companies making wonderful trucks, but oh boy the cost! Anything from €165.000 for a second hand 4x4 to €841.438 for a 6x6 MAN with an elevating roof and motorcycle carried on the back. We were getting there, eliminating what we couldn't have, unless we could win the lottery (unlikely as we don't do it)!

On the Fuss site there was a link to a travel show for Overland Campers in Bad Kissingen near Frankfurt Germany. This was in 2008, and with tickets booked we left the UK and headed to the show. It was a fantastic eye-opener and I'd advise anyone contemplating a build like ours not to try without going to Bad Kissingen first. The people you will meet there and the information they pass on is worth more than money can buy and it will save you hundreds if not thousands of pounds, not to mention time and frustration as you get into the build.

The best bit of advice we received was not to build the camper on a modern truck chassis. In Europe they are great for comfort and excellent fuel economy, but take them into the mountains with thin air, or fillthem with dirty diesel and they will just stop. So you will be stranded with the only solution being very expensive repairs aided by the use of a computer, not a set of spanners and a hammer!!

Back in England it was back to basics, with a walk to the newsagent to buy Truck Trader magazine, oh we live the high life and you have to start somewhere. There we found our truck which was a 1992 DAF ex army truck with just 1,400 km on the clock - unbelievable! The truck was in Cardiff so we made a phone call and were relieved to find that it was still there. Then we  (actually I) got cold feet so it stayed in Wales, but a couple of weeks later thumbing through the latest edition of Truck Trader I noticed that it was still there. This time I was decisive we got up at five one Saturday morning and set out for Cardiff to check that truck out.

Through the wire fence it was love at first sight - it was the truck for us. We took it for a very quick test drive and the deal was struck (and it was true that our truck had never done any work). We didn't have all the money at the time, so a deposit was paid and it was back home to raise the required funds by selling anything that was not nailed down (and a lot of stuff we didn't need with our new found freedom) and by working every hour we could and saving every penny we made. By June 2009 we had raised the final payment and it was off back to Cardiff to collect our truck and future home.

As the truck had never been registered, we borrowed some trade plates, and fixed the insurance and we were off, although finding reverse and not second gear as we pulled away from the dealer's was not a great start for the journey home, but apart from that it was uneventful.

Back home our truck sat in the garden for a few months, which became eleven altogether. The original plan was to register the truck, drive it to Germany and get Omcar to build the box. Like many fine plans in life, this one was strangled in red tape, so we had to rethink.  The objections included the truck can't be registered without a body, blah blah, "needs a tacho", said VOSA, "no it didn't if it's registered as a camper" said Portsmouth vehicle registration. It was a mad few weeks.

Step forward Barry, he of Gray Horsebox and Race Homes (UK) Ltd, who was delighted to see our truck, and the beginning of our dream coming true.  As Barry was very busy at the time he allowed us to use his workshop, tools and tap him for advice to help keep the cost down and allow us to build our truck, and although we had a few disagreements along the way this kindness from Barry is something we will always be grateful for and will never forget.

While the chassis was being extended and the box being built, I was attending Chichester College evening classes on a cabinet making course, to enable me to build the inside. I would like to thank Iain for all his help and patience in teaching an ex bricklayer how to build these quality units.

Plumbing was relatively easy and thanks to C A K tanks for all their help and advice.

Electrics were more tricky, and finding an electrician who can wire the living area in 12 and 240 volts while still being able to use the truck electrics which are 24 volts was going to be difficult. Luckily for us we found Nick who always enjoys a challenge or so he tells me and I was amazed that 12 and 240 plus 24 volts is possible!

Lorraine and I have both taken and passed our HGV driving tests, and in addition we have also both attended an off road driving course in Pembrokeshire where we put the truck through it's paces.

What made you choose this one?
It was fantastically low mileage 1500Km, ex army and never been used.

Main criteria for this project?
Overland camper large enough and comfortable enough to live in full time.

Modifications undertaken?
Chassis extended by 47" to prevent large overhang and slope the back reducing the storage space.

Modifications yet to do?
None

How does it perform?
Fantastic. We have just returned from the overland ttravel show in Bad Kissingen Germany via Bruge, Antwerp, Amsterdam, Uelzen, Bad Kissingen, Liege, Lille and Dunkerque. While MAN and Mercedes 4x4 were bogged down in the mud (mainly due to poor driving) our wonderful truck ploughed through it with ease.

What would you do differently?
Nothing

Comments (7)

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written by Scott, July 20, 2011

Excellent write up Phil, lots of detail! Glad you guys got back from Bad Kissingen safe and sound, ( I met you both there ). I look forward to bumping into you again sometime.

45/150
written by E M Wynne, July 20, 2011

you extended your chassis...who extended your propshaft

propshaft
written by Philip Woods, July 25, 2011

Hi

The original section of propshaft was removed and taken to Propshalf Services in Feltham Middlesex. They advised us that to extend this propshaft would make it to long, it would break.

They manufactured a new front section of propshaft with a bearing. This was attached with a new bracket to the truck. So the front section is the new propshaft the rear section is the original one.

The propshafts had to be balanced and lined up to prevent it from vibrating. Luckily one of the guys who helped build the box had experience in doing this. Good luck.

chassis
written by Philip Woods, July 25, 2011

PS The chassis was extended by Gray Horseboxes and Race Homes UK Ltd as part of the work they did making the box. It was extended by 49". The chassis was welded and bolteed.

Bad Kissingen
written by Philip Woods, July 25, 2011

Hi Scott

Great to hear from you. Hope you enjoyed Germany as much as we did. Look forward to seeing you on the road

Nice one!
written by Jago, August 02, 2011

Hi Phil

Sounds like you had a similar experience to us when checking out the the Bavarian options - lovely trucks but the cost of a nice house!
We took a similar route but I couldn't do the build myself so got Overland Vehicles on the job.

What are you travel plans now?
Any additions or modifications planned?

Cheers and happy travels
Jago

Off road practice
written by Tony Evans, September 18, 2011

Hi Guys,
Just a quick note to gauge any interest or ideas on how to organise some off road practice with our Leyland Daf 145 campers.
We have had our camper for 2 months and completed 2000miles of mostly road trips. I would like some practice off roading but we are struggling to find a suitable venue. Iv approached a few 4x4 friends but they are concerned that the weight/size of my truck would be a problem to recover if I got stuck.
I thought it might work to organise a gathering of similar vehicles to practice in the rough and also share experiences - ideas on our vehicles.
Let me know if there is any interest or ideas of where/when we could meet.
Tony Evans (based in Gloucestershire)
This e-mail address is being protected from spambots. You need JavaScript enabled to view it
P.S. Im trying to increase engine power, has anyone fitted an intercooler? Its listed as a factory option but I cant find a supplier. Any ideas?