froggy
Posted a lot
Posts: 1,099
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Fancied getting a camper for a while and see plenty at work for mot etc and they fall into two camps . The first being older stuff which usually looks like its been dipped in underseal up to the door handles and powered by a 1.7 petrol or prehistoric diesel and the nearly new stuff with all mod cons and a modern common rail diesel that can sit at motorway speeds without sending the occupants deaf . Price wise the bottom end stuff is anything up to 5k and modern tackle anywhere from 12-40k , for something that will sit around for most if the year I set a budget of 5k to buy and build my continental express . After seeing some cheap stuff in various states of decay I dropped on a 1991 ducato maxi 2.5 d with no power steering and a storming 75hp diesel with 5speed box  A quick trawl through the shed and all the ingredients are there  My last Saab 234r spare engine which will get a quick freshen up  T25 from the donk which was lpt and 68k so minty fresh and an intercooler from a road sweeper  New aero clutch and 240mm flywheel  Plenty of looms , stock map sensors di ecu etc .  Enough bits to build a 3" downpipe  Corsa epas column which tucks in at the bottom of the column and uses an eBay signal generator to drive the ecu The only parts I hadn't got were a set of red injectors and a 4.45 box to match the vans diff ratio but sourced them last week . I can't seem to find the ratios in the ducato box but they are most likely 1-1 in 4th with fifth slightly overdriven . The Saab ratios are a little taller but there are options to go down to 15" wheels with smaller tyres if needed but the goal is 80mph comfortable cruising and enough grunt to go up hills without crawling So far the van has cost 2.5 k with a bit of cosmetic bodywork needed and £100 for the injectors ,epas controller and 4.45 box . If I remove the ducato fuel tank it looks like the 9k unit will go in its place which will make use of the in tank walbro pump and sender . With a standard tune for the FPt 2.3 engine will be 185hp to start with but change to a tdo4 and a bit more boost will be 250hp 280lb/ft |
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Last Edit: Mar 1, 2013 23:16:45 GMT by rmad
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10mpg
Club Retro Rides Member
Posts: 4,253
Club RR Member Number: 204
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Awesome, looking forward to this, I thought for a second there you were going get all dieselly with us!
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The Internet, like all tools, if used improperly, can make a complete bo**cks of even the simplest jobs...
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`state
Yorkshire and The Humber
Posts: 1,215
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This is going to be good.... Ive wanted a camper for ages but cant afford a really decent one,and don't want to buy a cheap one that will turn into a money pit.
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Look at all the plastic people who live without a care.Try to sit with me around my table,but never bring a chair.
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froggy
Posted a lot
Posts: 1,099
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We considered a t5 volvo drivetrain but I have so much stuff lying round its a no brainer .
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froggy
Posted a lot
Posts: 1,099
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Column in , just need to butcher the pedal box and add the clutch and brake switches from the 9k ready for the cruise control system  |
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Colonelk
Posted a lot
Posts: 3,740
Club RR Member Number: 83
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I like the idea behind this.  looking forward to see what you do |
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froggy
Posted a lot
Posts: 1,099
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I've had petrol and diesel v8 American campers in for test and they are just as feeble as the old European stuff performance wise . While all the glass is out for the respray il put some privacy tint on so we can make use of the rear on long journeys . A stock aero clutch would most likely do the job but I have a spare race clutch that can hold 500lb/ft so no danger of slip going up the col de Turini   Decided to use a td04 15t instead if the t25 and start off with 280hp 300lb f/t as it spools quicker than the t25 with full boost at 2800rpm Struggling to find much data on these for the front geometry as it looks like its set up to make the steering light which is fine but might need some adjustment to caster and camber to run at high speed . Front seats next and trying to find some 9000 aero items which are superb and fully electric /heated |
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This is an awesome project.
Looking forward to more updates!
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'03 Porsche 996 C2 3.6 - Sort of Retro
'84 Porsche 924 - Definitely Retro!
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froggy
Posted a lot
Posts: 1,099
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Power steering done after a lot of lying upside down making templates to stop any flexing at the base of the column and its so much nicer to drive . Steering is still very slow but parking is effortless .  You can see the little signal generator dangling by the motor and it only needs about 1/2 power before it gets a bit too light . Bagged a pair of aero seats and a td04 this week so it will be 250hp with plenty of midrange grunt . I forgot I still had the 3" system on the donk so just need a length of straight tube to get the tail pipe to the back of the van . The grille is quite deep so I might be able to carve the inside out to make room for a decent sized intercooler but I'd like to keep the fiat rad as its a good size and has twin fans on it already . |
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froggy
Posted a lot
Posts: 1,099
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Mar 13, 2013 20:12:28 GMT
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Made a start on the body this week and other than the rotten window frame which had rotted out the sill I only found a few holes where previous bodges have festered  There was not much holding the window in and the water has been running down onto the inner sill and rotted it out  A few holes round the back but all the inner panels are sound  As normal all the cut edges from when it was converted have been left bare so all the glass has to come out to treat them before getting painted . A few more measurements and at the current ride height the fiat shafts run downhill by 20degrees and the ground clearance is 9" so dropping down to 65 series tyres means I can raise the front spring platforms by 3" and at the rear move the axle on top of the springs to make a 5" drop which will put the front into a fraction of negative camber rather than the positive it runs at present . The lower I can get the motor in the easier it will be to fit as there is a big box section that could make the gear linkeage a pain . I could notch it but that would mean the van needs an iva and I'm very careful now not to offend the build police on here On the positive side it turns out I have 5x118 pcd rather than 5x130 so a good choice of wheels available and I noticed my old 9000 still has the stainless 3" exhaust system on it so I just need a length of straight tube to get it to the back of the van . |
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Last Edit: Mar 13, 2013 20:15:31 GMT by froggy
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froggy
Posted a lot
Posts: 1,099
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Mar 20, 2013 21:18:17 GMT
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 Got the right wheels on and have two small patches to let it around the bottom of the screen and the welding Is all done . The rotten window frame being the worst as the insides are full of insulation and polystyrene .   Done some reading and picked a few brains about lpg on turbo engines and its a no brainer for this build as I have room for three tanks and the earlier Saab lumps take to Gas pretty well just need to set the system up using a wideband afr gauge to keep it all happy . |
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froggy
Posted a lot
Posts: 1,099
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Still bogged down with rusty bits but there is light at the end of the tunnel with just the front screen frame to sort  A mixture of tissue paper expanding foam and fibreglass in there The screen frames are notorious on these vans due to the clever window seal that let's water run from the top of the screen to the back of the seal and then sits on the frame rotting it away in the bottom corners .   Grotty   Notty Bit of changing room action inside  The seat boxes bolt in so can be moved back to allow the seats to recline fully on the passenger side at least once they are turned round . Got a flange made to fix to the diesel tank to take the 9k pump assembly as it leaves the fiat guage untouched and the return flows into the plastic pot so shouldn't have any surge problems , can't see any high g force cornering happening . Looks like its easier to leave the ecu in the engine bay and run the feeds from the fuse box which is behind the glove box . Need to track down a smaller steering wheel as the bus sized one is redundant now the epas column is in and it allows the seat to recline . By coincidence the clips on the aero seats match the fiat inertia belts , maybe a more common size back in the 90,s Got some more info on the lpg system and it looks like the supply side and vaporiser are the key to getting the power on boost , I have specced a unit that can support 330 hp with injectors to suit and the front end kit will be around £600 . With the two tanks I want to fit will come to just under a grand so il try it on petrol and see if I do the mileage to recoup the investment . Haven't done the maths but I can't see this doing more than a couple of thousand a year needs further thought or more truthfully I might get bored with 260 hp and start turning the wick up a bit |
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Love it!
I'm wondering how all the crockery will stay in place when driving.
Are you gonna rebadged it to a Saab / Scania? Like a one-off prototype.
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 Click picture for more |
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froggy
Posted a lot
Posts: 1,099
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Just these decals to go on the front wings  |
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10mpg
Club Retro Rides Member
Posts: 4,253
Club RR Member Number: 204
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I ran a Saab 900 Turbo on lpg, worked fine, but needed a sniff of petrol at the higher boost to stop it leaning out.. Most of the kits allow you to add some petrol at high load/rpm, depending on which one you're going for...
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The Internet, like all tools, if used improperly, can make a complete bo**cks of even the simplest jobs...
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I thought this was being run on vegtables from the title.....
No seriously lol coolest idea for a camper...... my Dad had a 2004 Ducato and that thing had more rust than this. Keep up the good work you should have an awesome touring machine.
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fantastic project! looking forward to seeing this up and running!
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froggy
Posted a lot
Posts: 1,099
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Apr 18, 2013 17:33:01 GMT
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Finally run out of things to weld so its in the paint shop for a colour change ,  Every last bit of grot is gone so it should be good for another 20years once it gets the waxoyl treatment when it comes back . I mulled over using the original colour but the lads in the paint shop have just done a truck in a very bright red or f**ck off red as they described it so I've gone the extra mile and prepped the door shuts etc so it all matches     The captain chair conversion is causing a few headaches as the aero chairs are a bit bulky so I've had to add a second set of runners under the swivel plates that allow the chair to slide sideways towards the centre so it can swivel round . Still in budget as long as I don't have to spend too much on bits to refresh the 234 but I'm only missing a new main timing chain and bottom end bearings as long as the rings are ok . I pulled the shifter out of my 9k and it looks like it will need some work to shorten the throw as the van gear lever is 3ft long and il need to rig up a short cable and lever to get across the gate for reverse . My other half has booked some campsites in Brittany in may so I've got til next Friday to finish it , obviously still with diesel power but it means that all the other work will be done so I can concentrate on the engine swap . |
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pabblo
Part of things
Posts: 435
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Apr 18, 2013 21:37:03 GMT
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Inspired project! Nice job with the bodywork looking forward to seeing some pictures when it's painted.
Always liked these old Fiat Ducato vans but then again I like old Fiats. Should move along nicely once you got the Saab running gear in. Hope you meet your deadline for the holiday.
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froggy
Posted a lot
Posts: 1,099
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Apr 22, 2013 21:49:25 GMT
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Looks a bit brighter now    Trim and glass back in tomorrow then get the interior ship shape |
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looking forward to see what you do 
