Building a "Coachbuilt" Self Build?

[Wissel]

This is what happens with lockdown boredom. Ideas form

I'm thinking about building a larger van, likely a 7.5t with a 5m box and overcab. Thing is, I dont really want to convert a normal box-van, I like the idea of building something like this:

Just an idea atm, but I could do with a few pointers if anyone can help?

Firstly - the base vehicle.

I'd like something that goes on forever. Likely a lorry chassis like the Mercedes Atego above, but possibly a higher weight rated Iveco Daily/Mercedes Sprinter etc. Recommendations or ones to avoid?

It would be a huge bonus if it were a simpler engine (no canbus) if possible, but not essential.

Secondly - the box construction.

Has anyone build a box themselves?

I've done a small amount of research and seen most manufacturers use a composite sandwich construction. This seems fairly easy to work with, but not found a supplier yet. Or would an aluminium frame be a better start?

Of course I could start with a box-van, add strength, new roof and build an overcab. But as I'd want side lockers and the look of the above image, it's probably easier to start with a plain chassis?

Anyway, any thoughts?

 

[Stonemags76]

Didn’t MANGOFORTH build a box for his?

 

[gpat]

Good effort. 10 out of 10 for setting your self a challenge. If it looks like that when you are done you will be looking at a new career.

I would search out how horse boxes or race day wagons are built. Not exactly the same but some of them are coach-built. Especially the posh ones.

I think Bradley Wiggins had a custom made one. A bedroom was added just for his ego to stay in.

 

[gpat]

PS forget the Bradley Wiggins one. I was getting confused. His was just a massive sprinter conversion

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[Stonemags76]

Here is his thread. Aluminium I think??

The Big Lorry to Camper Conversion

So, long story short. Wanted a motorhome, ended up with a lorry. The body was rotten, kept it anyway. A quick camper conversion has spiraled out of control massively..... I've started the work already but I'll drip feed the photos over the next forever. Feel free to help and Enjoy. In the...

www.motorhomefun.co.uk

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[SandraL]

Some time back, years?, I read about a trailor build for a stationary engine plus living accomodation, probably here on mhf.
Believe he used aluminium extrusion frame for walls and used insulated panels inserted into the extrusion.
A good read and lots of pictures, anyone remember where or who it was?
Think it had a steerable front axle.
The aluminium system might have been used on lorry trailors, there were off the shelf parts for corners, tee joints etc.

 

[funflair]

If you were building it as an overlander you might want an alloy frame but otherwise I would be inclined to just copy what Concorde, MORELO, PhoeniX etc do in Germany which is aluminium or fibreglass skins on a foam core, I am sure that you could buy the composite panels but not sure that they would come big enough for a box side or roof, I know that MORELO and N+B both press up their own panels but not sure about PhoeniX and Concorde as I have not seen that side of the production.

All of these type of truck have a "road floor" that is fixed to the chassis and then they have an underfloor area that houses all the tanks and services, this is all boxed for rigidity and then the internal floor is fixed on top with all the furniture on top of that.

As for chassis the IVECO Daily seems to be the most popular under 7.5t and is a good reliable workhorse and the earlier versions were not so reliant on electronics as they are now. Going to a proper truck chassis you would need to take care with the build to keep something back for a decent payload, as you suggest Mercedes Atego are popular but not the lightest IVECO Eurocargo are lighter but not as well respected as Mercedes of course, then you have MAN which used to be popular but I believe the hardware for the latest emission regs has made it difficult and they have been dropped in favour of IVECO or Merc.

 

[funflair]

Some time back, years?, I read about a trailor build for a stationary engine plus living accomodation, probably here on mhf.
Believe he used aluminium extrusion frame for walls and used insulated panels inserted into the extrusion.
A good read and lots of pictures, anyone remember where or who it was?
Think it had a steerable front axle.
The aluminium system might have been used on lorry trailors, there were off the shelf parts for corners, tee joints etc.

Sadly he passed away, but was mentioned in a thread a few days ago, he was called Peter and I believe he went under the username "listerdiesel" although I think his stationary engine was a Ruston Hornsby.

 

[Minxy]

You can buy aluminium wall frame kits used in houses which you might be able to adapt for a MH box frame.

 

[funflair]

Have a look HERE although these are A class it will give you an idea of what I described above.

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[busbuddy]

There used to be a company in holland that would build the sandwich wall panels to any spec/size so they must be available somewhere

 

[timetochill]

Some time back, years?, I read about a trailor build for a stationary engine plus living accomodation, probably here on mhf.
Believe he used aluminium extrusion frame for walls and used insulated panels inserted into the extrusion.
A good read and lots of pictures, anyone remember where or who it was?
Think it had a steerable front axle.
The aluminium system might have been used on lorry trailors, there were off the shelf parts for corners, tee joints etc.

Went under the name of lister diesel brilliant guy very helpful sadly passed away

 

[A and B in the Huzzie]

There used to be a company in holland that would build the sandwich wall panels to any spec/size so they must be available somewhere

https://cvr-uk.com/ seem to do what you're looking for.

 

[Wissel]

https://cvr-uk.com/ seem to do what you're looking for.

Now that is really interesting. They can produce huge panels, all CNC routered, ready to fit.

Might be a scary quote, but worth a call I think.

 

[Mhambi]

I built a box on the back of a Unimog. Its a big task and very expensive. If that's not an issue then it is really enjoyable.

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[tacr2man]

There are a few suppliers in UK , and some do body kits , if going for ali exo skeleton type build. It can be difficult getting one piece side panels for larger builds. and as Mhambi says the panels can be very expensive . If you have ny local horsebox builders nearby they can be a good source of info . Composite panels are easier to source than ali faced panels .
https://www.truckcraftbodies.co.uk/types

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BTW handling large panels can be a logistical problem in itself as they can be surprisingly heavy , especially when putting on a 8Ft x 20ft roof !!

 

[glenn2926]

Would the panels used to build fridge truck bodies be any good?

 

[Wissel]

Just watched a very useful video from a guy that had the box CNC'd from 5 layer panels (GRP outside, ply, insulation, ply, GRP inside):

The box was £5700 delivered which I thought was quite reasonable?
Then another £1400 in glue and I'd guess £500 in aluminium.

Mhambi - Is it too rude to ask how this cost compared to yours? (PM if prefer?)

 

[Wissel]

This thread has given me an idea:

Nice self builds.....

We have the ugly thread so I thought we might have a nice self build thread. All welcome PVC, coach-built, demountable.... I'll kick off with this VW transporter based one off gumtree...

www.motorhomefun.co.uk

This van...

...has a demountable living area. Now I'd guess that there are standard 7.5t mounting plates to accept shipping containers etc?

If so, then this could be switched to a new van in time, if the base vehicle becomes BER?

Maybe removed and sited if the base vehicle developed a fault that meant garage time?

I like this idea after having vans blow up. Twice. Not a fun event when fulltime.

 

[Jamesh]

I think Argos and dfs had demountable truck bodies...

Haven't seen them recently.

You could do one on a iveco or lt46 chassis.

Cheers James

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[Jamesh]

How about this for a compact van???

https://rover.ebay.com/rover/1/710-...0001&campid=5338547443&icep_item=124520959031

Cheers James

 

[Terry]

Hi David, I had a friend who used to buy ex BT vans , extend chassis 6ft and fit a Luton cab on. He bought all the extra panels and skirts and Luton from a fibreglass co at Barnsley.
Have you thought about a library bus ?
My X ambulance was made from Ali bonded to 6mm ply bonded to 30 mm styrofoam bonded to 6 mm ply bonded to Ali with a very basic steel glavenised framework ...top bottom and a couple of legs in the middle.Bit like a skinny ladder.
I have made a similar framework and fitted it to a pick up but it was always too high in my opinion.
I have also done a 27 seat 5ton coach that gave plenty of room

 

[Jamesh]

Or this......

https://rover.ebay.com/rover/1/710-...0001&campid=5338547443&icep_item=363264220776

Cheers James

 

[Jamesh]

These guys build box vans...

https://rover.ebay.com/rover/1/710-...0001&campid=5338547443&icep_item=293946817842

Cheers James

 

[mitzimad]

i looked at all the options for a larger self build than my ducato but they all seemed to be to expensive to old too slow or to many miles the cost often worked out as more than you can buy a prebuilt one for

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[Terry]

Only problem with a truck type wagon is MPG 13 to 17 ....at least with a van base you are going to get mid 20s.....may be better/. Cheaper getting a RV

 

[Terry]

Trying to remember name of a company that makes Luton backs and fits them to lo loaders ,,,,just down the road from Barnsley football club

 

[Wissel]

Trying to remember name of a company that makes Luton backs and fits them to lo loaders ,,,,just down the road from Barnsley football club

Think a flatbed Luton, something like a 5-7.5t Daily/Sprinter, would be a good choice tbh. "if" I could build a demountable living shell.

I know it won't be cheap, but if I could build the box to last, along with maybe a low mileage 2015 van, I think I could build it for around 30-35k with the spec we are used too.

Then, once the van got older, I could buy say, a new Daily/Sprinter and add the box. It could work out very cost effective over time, plus be exactly what we want.

Looking at the high end models like Hymer, Concorde, etc, they haven't changed that much inside over the last 20 years. Built well, maybe my (possible) box could last that long.

 

[Terry]

Hi David the back bit is nearly always bolted to the chassis Only A class are built as a one piece and even they are bolted onto chassis.
Thinking out of the box I would look at some of the futureist looking small coaches etc. Very easy to remove glass and sheet over, then add your own where you want them.
If you still have access to the web site you created for me have a look at the pine bus I did Wish I had kept pics of a lot of my conversation vans on a pen drive etc, I lost a lot of data when a hard drive failed.

 

[Mhambi]

Just watched a very useful video from a guy that had the box CNC'd from 5 layer panels (GRP outside, ply, insulation, ply, GRP inside):

The box was £5700 delivered which I thought was quite reasonable?
Then another £1400 in glue and I'd guess £500 in aluminium.

Mhambi - Is it too rude to ask how this cost compared to yours? (PM if prefer?)

Hi Wissel, Havent watched the video as yet but that sounds about right was about £5500 for the panels and just over £1K for the Aluminium. Glue was not as much as that, I think I spent about £800 on glue, Then there is the Welding of the Aluminium frame, another £1k windows £7.5k door £2.5k, toilet £4k and the list goes on.........

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