Introducing my part built 709d

Stu709d

Guest
Well, where to start, bought the van a bit more than a year ago, had been done as a race day van, basic kitchen unit and bed, rear of van open to transport quad bike, with a really heavy tail lift for loading. First job was to strip it back to a panel van, removing all the ply lining etc, when I discovered mice living in the roof insulation who where swiftly evicted by means of traps and throwing my cat in there! Now I could see what I had to deal with it was on with the bodywork, of which there was lots to sort, basically remaking and welding on bottom 10 inches of van, roof hatches had to be removed, metal work sorted and refitted to stop the horrendous water leaks, previously badly fitted aftermarket crap windows had led to loads of rust in van sides and yet more leaks, but, I'm pleased to report, a year on doing it at weekends it's now all done and in primer ready to start the re spray.

Internally the van has been lined with loft insulation, with a layer of silver foil bubble wrap insulation over that, acting as a moisture barrier, then fully lined and sealed in 6mm marine ply, all wiring for 240/24/12v electrics and gas pipes run internally through walls before lining. Walls have then been smoothed and wallpapered and have started fitting/building furniture, cupboards, etc. carver water heater installed.
A wood burning stove has been fitted, onboard 140l water tank, lpg refillable gas bottle kit, 3 3'x2' solar panels fitted to roof, connected via dual battery charge controllers to a bank of 6 banner leisure batteries, 2 linked as isolated 12v, 4 linked as isolated 24v, panels charge at 12v each, so one panel charges 12v, other two linked to charge 24v, these also charge the vans 24v batteries via the inbuilt split charge on the controllers. These have been fitted and working for 3 or 4 months now and on a reasonably sunny day will charge all 8 batteries from more or less flat to fully charged in one day, the idea being I never need to go on hook up and van can be left and is always fully charged. Crap windows that had been fitted have been removed, and new double glazed units fitted into my own custom made frames which were welded into sides of van, see pic, it's one of the few I've taken so far, and it looks a bit different now but shows the near side window fitted. Glazing is super efficient argon filled warm edge glass which I had made to order to fit the frames and have then been bonded in, like a windscreen. This has instantly stopped all condensation, and if you light the wood burner in the morning the van stays warm all day from burning one heat log, even when it's minus 5 outside, there's also a 24v eberspacher diesel night heater fitted as back up.

Sounds like it's nearly done but unfortunately still got a way to go yet. Not fitting toilet/ shower facilities as these are readily available, have a Portapotty for emergency use, and there's always the bear method!


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Not the best pic I know, will update at weekend with more pics,
 
Looks like a big job but good luck. It will be very satisfying when finished. Keep us updated with progress.
 
That's a big van, and a big job sure it will be brill once finished, hope to see the updates soon.
 
Yeah, certainly been quite a task, spent months, grinding and welding and sanding the bloody thing, been times I wished I'd bought a mini van! Be worth it in the end, I intend living in it full time when its finished, hence the effort to get it as self sufficient and comfortable as possible, maybe not how everyone would do it I'm sure but it's the uniqueness that appeals, and the fact I'm doing it all myself, there's something about self building you don't get from buying one already done
 
Wooie1958 said:
You`ve probably already seen this but just in case you haven`t Alternator from 1994 Mercedes 709D Panel Van. Breaking Complete Van | eBay
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Thanks, I have but haven't been able to get in touch with them, tried 10 times I reckon, don't think the bloke actually wants to break it! Could probably get most of what I need from it as well, it's identical, I will try again now you've reminded me about it, thanks

Just tried again, went to answer phone again, left a message again, I don't understand people who advertise things then don't answer queries, not gonna sell much like that is he. I don't quite need enough bits to warrant buying a shed and breaking it or I'd do that, and storing all the parts or a half stripped van would be a bit of a headache, I've already got one scrapyard dodger
 
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Photo update

Quick update with some pics, that's as it sits now, I'm planning on finishing this year

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Good job so far. Always liked the t&g wood interior finish, makes the van more homely and will go great with that stove I can see.
 
More on the roof

Thanks, got a bit more done on the roof today and actually remembered to take a pic, I've had to do this to the full roof, bloody hard work getting in the edges in the channels, just needs a quick go over with some 600 grit in morning then throw some paint at it, one more section to go

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F...ing weather

That's torn it, my roofs now bare metalled and the weathers turned sh.te, and just seen a forecast says it's getting worse later, I hate working outside! Thrown a plastic sheet over it for now, try and keep it dry, daren't try and do any painting, it'll just get ruined and il have to do it all again
 
Love what you have done will have to get my pictures uploaded to show you ours:have fun:
 
Hi all

Thanks for all the comments, sorry not been on for a while or done any updates, been a hectic few weeks for me, not had much time to do anything to van so not a lot to update about. I have now started on the passenger side internally but only managed to get a bit of framing done so far so not much to show. The weathers not been good enough to do any more paintwork so no progress there either, my xmas deadlines looking a bit unachievable at the minute! Im doing it all myself, on my own, and working 5 nights a week doing 12-14 hr shifts so im struggling to find time at the minute to get much done
The ceiling is textured wallpaper, looks and feels like fabric, the quilted effect is the print on the paper. Was toying with the idea of doing it in proper fabric when i stumbled across the paper on ebay, gives the same effect but without all the hard work! Quite pleased with how it looks, just wallpapered straight onto the ply lining after smoothing the edges and screw holes with wood filler. The walls are also just waterproof vinyl wallpaper straight onto the ply.
The woodburner is great, chucks out massive amounts of heat and looks great in the dark with the flames through the glass. Initially had it with the flue out the back but was having problems with lack of draw, especially in windy conditions, when the wind would blow down the flue and fill the van with smoke. After some investigation on the net discovered you need at least 30feet of flue to get enough draw to pull it round the 90 degree bend that you have to have in for rear venting, changed it to the top and problem solved, the draw is now sufficient enough i can have the door open, even when windy, and the smoke still goes up the flue as it should. Wish id known that before hand, would have saved a lot of work and time.
Would love to see some pics of other peoples self builds, there only seems to be a few of us doing them, would be good to see what/how other people have done things.
Will update with some more pics when ive got a bit more done
 
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