Trustys Build Updated and Re-Written


Trusty’s Build and humble beginnings 

Below are some of the build pictures with descriptions.  Not  all. but it will give you a good idea of how we built her

We bought our old Transit van Mk 5 locally and named her


Trusty Day after we bought her.

Bought Trusty in excellent condition for an old transit ..with a genuine 52 thousand miles on the clock.. She had been standing up for quite a while. Previous owner had dragged her out of storage and mot’d her. She is in excellent condition all round for an old transit..exceptional really!! 

As we intended to do a fair bit of mileage in the coming months.. I gave her a good going over and , I  decided to replace  all the brakes inc cylinders. cam-belt. all other belts water-pump. Front shocks and ball joints and prop-shaft bearings, the rubber ones. main UJ’s were good and as they are pressed, I decided to leave them alone. The parts at the time were dirt cheap on ebay, seemed  a no brainer not to..

So with all that done, we started the build Guy we purchased her from ( we like to think rescued)  had started a camper project and lost interest. Fortunately He had installed the windows all round, which saved me a job. It had an interior of sorts an old piece of thin ply fixed to one side,and the same on the ceiling. (in the Pictures). I ripped this out  and the front partition which BT had originally installed

Then we set about converting her to a camper

 I re- fitted the partition to the rear to give us a 2 foot space behind,and separate the van from the proposed toilet and gas bottles etc,  Accessible from the rear doors.030

Removing this partition from the front, opened up the van light wise,and allowed me to build an overlocker above the cab.  I then set about building the roof and side battens to hold the paneling. I used roofing battens these are dirt cheap, tannelised, and ideal for the job. Available at any good wood yard. cost £10

                                                        Insulation and boarding.

So I set about trolling eBay and Amazon for the right stuff. After seeing the prices I held back a little, popped off to my local caravan center. Took a look at the stuff they had, similar to eBay,  And then it struck me. it’s almost the same as the duvet covers on your bed,except they have a cotton lining sewed to them.

We as it happened. had loads left over from the Flat  it took 4 king size to do it..  a good pair of scissors and some spray glue, (use the better Quality as it more heat proof) and hey presto our van is now 20 tog,  Cost ?? Zero. I worked it out to £180 quid if you needed to buy materials from eBay to do it. and 4 king size quilts from Home Bargains were £40 if you had to buy them.

Once the roof and wall battens and insulation were in..I lined the ceiling and walls . ( I used 4 mm ply. light and easy to cut and mold)  Bought it cheap from a re-claimed woodyard. £3 a sheet 8×4. After installing all electrics,cable etc underneath them first.

Cut all holes for LED light, and switches.As you can see from the picks fairly easy to construct, just one point though ?? Make sure when you fit the  panels, you mark on the outside of the boards, where the batons are underneath. This saves a load of hassle when you come to fix things to the walls and ceiling. pictures below


Then I set about finishing  the over cab and constructing side lockers . these were fairly straightforward to do. I used a combination of 1×2 inch and 1×1 inch pine which I cut down from the bed slats from my Brother. The base of the blanket box over cab is made of 12 mm marine ply, which also came from my brothers. Good old Bro…The locker doors were salvage from the old caravan we bought.

                                                                    Wall Covering

Lined the  van with felt. I bought from E bay at £30 for the kit,inc 4 tins of high temp spray glue. Panels from eBay seller locally, cost me £30. Then I set about constructing the over cab and bed lockers. these were fairly straightforward to do. I used a combination of 1×2 inch and 1×1 inch pine which I cut down from the bed slats from my Brother. The base of the blanket box over cab is made of 12 mm marine ply, which also came from my brothers. Good old Bro..

The Bed

 Teresa wanted a full size bed, difficult to achieve in a narrow transit. I would have preferred a cross bed, but Trusty is around 6 inches too narrow to do this. so full length pull out bed made and installed . 

Again I scoured about for materials, luckily for us My Brother used to buy container loads of furniture returns from ebay, and so happened to have a huge amount of pine bed slats hanging around, again that’s what we used. and again cost. Zero.


Fridge, and Kitchen Area

As mentioned before.  Sourced  an old caravan of ebay £150 including the fuel to fetch it. Had a nice 3 way fridge in, plus I used some of the furniture and sink, plus the water heater as well. Made framework again from cut down pine bed slats.11

Basically a box type frame (same basic construction as overhead/side lockers) which I mounted the fridge on and built a cupboard above. other cabinets in this area were constructed from modified parts from caravan. amd reclaimed wood. panels etc. Added a microwave. some table and cupboard areas to the side.all constructed from cut down pine, and re-used caravan parts.

The microwave is no longer in now. as we  hardly used it and it was heavy. I have replaced that with a lock in table. underneath the sink is a lot of storage, and also This area, is where the 70 liter fiamma water tank and whale heavy duty pump, are located. This powers our portable shower as well.


I have constructed a 90 liter waste  water tank underneath the transit mounted between the prop shaft and inner sill. This I had to make myself as I could not get one anywhere at the dimensions needed.

Sink Tap came from the caravan as did a lot of the water pipe hot and cold. as mentioned I fitted the water heater, which at the time worked well. but it never held enough water for a decent shower. and took up too much space. on the refit I have removed it and replaced the whole system with an LPG heater more about that in the refit section. the black formica tops are again from my bro’s place and free. 


                                               The Rear Compartment (update)

As I mentioned before, I left a two foot space behind the rear partition for toilet and gas bottles/storage etc, At an early stage I decided. that we did not want the toilet in the living sleeping area,  a little inconvenience getting out of Trusty to go in the back doors, proved to be no problem.

Originally I fitted waterproof panels to the insides and made a wet room, this proved to be practically useless to us,as it leaked into the flooring and was too tight. So I opted for  a portable gas shower, which does the job nicely.

The shower is used outside of the compartment , we have a fold shower tent for privacy. or we can draw over shower curtains on a rodding system we made up.between the back doors.  Works well. Not A class standards, but we are about functional and above all cheap.

In the left pictures can see the Gas low Self fill bottle system. which I stole off one else bid on it and I got it for a song. 

We are more or less,fully solar. with two main leisure batteries in tandem and the engine battery separate, or all can be used in tandem, via remote switches.                                                        

                                                      New Mod… Motor Bike Rack

May 2018

this is a new mod. We used to tow my Honda around on a bike Trailer, which to be fair was great when we were using it, but at 1133 cc and weighing 243 kilos was a pain. Plus the trailer 

I  dislike towing Trailers of any kind, they are a nuisance. and restrict you  from visiting many beautiful villages. If you make a wrong turn  down a tight road or Track, ( BELIEVE ME !! WE MADE LOADS )or even some Aires. you often have a hard job to turn. It always invariable means unhitching  the trailer with the bike on and manhandling it around..No Fun in 40 degrees, or black of night.

So After our last trip I decided a small 125cc bike and a removable  bike rack would be just the ticket. So, I set about making one.. below are the pics of what I did. And are now permanent mods to Trusty


Trusty with bike rack and nasty black windows turned to blue, by the magic Fairies

All in all it has done us nicely, I have definitely seen much better conversions than ours. but in 3 months and limited carpentry skills, (at the time)  we  were  happy with her as she was, but as I write this,  and after many miles and months of using Trusty, things need to be modified and altered a tad. Now I am refitting and altering some of the inside and out.

Trusty Changing Stages

`2018..Teresa recovered the Seats and made new Curtains all round.



This time round back in the UK we not only added the bike and rack, but reupholstered the seats. added new curtains, and added two single Memory foam extra mattress toppers. All Made by Teresa.

Except the memory foam of course. If we could make that. then this  Blog would not exist. and we would be swanning it up in a mansion somewhere in the Caribbean

Trusty’s improvements are always ongoing, as we think of things we need to add or take away. Please feel free to message us if you have any questions, related to self build. always happy to help if I can.

Footnote 14/01/2020

Trusty Has now clocked 92.000 miles. and 40.000 or so, with us..Bullet proof, as I mentioned, some knocks and scrapes, minor mechanical improvements. but still going strong.. going to fettle her up completely on return to UK. this year..we now have a narrowboat so its going to be easy to take her off the road for a few months and do it..when we get back in April..

Update 29/01/2020 

Fitted a cambelt to Trusty today.. Last one fitted 40.000 miles and 6 years ago.So a year over its recommended date, and 10 thousand miles under it. Old belt was in good order though. tensioner starting to wear. 

Did it outside the house, in Portugal..who needs a workshop ??

Belt Changes at 54.000 miles, and now 94.132 thousand miles. respectively. 


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