Renault Master camper conversion

[Cuthy246]

So the problem that warranted the gearbox coming out was that 6th gear would not engage. Thankfully not a disaster, the 2 springs in the 5th and 6th gear synchro had shattered. Also thankfully no damage to any of the gear teeth or bearings. One bearing has some minor pitting so I will replace it just to be safe.

Nicely machined gears covered in caramel sauce


The offending springs (item 43)

 

[JMS1972]

Something I've never attempted well done for having a go.

 

[nickk]

Good job,why the foil lining?

 

[MCKDAVID]

just a question for my own interest, what does all that wood add to the overall weight? looks fantastic, but I'd be concerned about adding un necessary weight? or is it not too bad?

 

[MCKDAVID]

Something I've never attempted well done for having a go.

Usually nothing really difficult, basic mechanical works / methods. In my experience the trick is that you need to be methodic, and are hopefully uninterupted from start to finish. Start with a good clean work area and lay it all out as you go in the order they came apart. Done a few over the years, in general they look worse than they are, once you get into them.

 

[slim_boy_fat]

It looks like the old Group 4 Securities prison transport with those rear windows

That was my first thought, but I didn't like to mention it.

 

[Cuthy246]

Good job,why the foil lining?

Two reasons, 1 is a little bit extra insulation as it is supposed to reflect the heat back in and 2 the main reason is as a vapour barrier so humid air does not reach the bodywork and condense

 

[Cuthy246]

just a question for my own interest, what does all that wood add to the overall weight? looks fantastic, but I'd be concerned about adding un necessary weight? or is it not too bad?

If anything I need softer springs or a couple bags of cement to calm down the back. I have probably put about 100kg in wood and insulation in the van. Max payload in the back is around 1 ton for this van so barely touching it. The cladding panels are only 9mm thick.

 

[Cuthy246]

Usually nothing really difficult, basic mechanical works / methods. In my experience the trick is that you need to be methodic, and are hopefully uninterupted from start to finish. Start with a good clean work area and lay it all out as you go in the order they came apart. Done a few over the years, in general they look worse than they are, once you get into them.

This 100%. You can repair anything if you just take it slowly and record what you are doing. Pictures and notes if needed. With experience you start to see oh that bit should go there without needing a diagram or pictures

 

[Cuthy246]

That was my first thought, but I didn't like to mention it.

Don't worry I can take it .
Window selection was a budget constraint, proper van windows are about £180 each for the ones that open. These were about £30 each

 

[Cuthy246]

So no update for a while, was waiting for gearbox bits to arrive. Pig of a job involving pressing the gears and bearing races off of the shaft to get to the synchro, also had a massive balls up doing this (the less said the better) cost me £140. About 12 tons needed to separate them. Anyway it is all back together with new seals and have taken it for a short test drive with nothing exploding or making funny noises. Gearchange is lovely and crisp now . Got on with wiring and kitchen unit while waiting and this is where it is tonight.

 

[jimbo84]

It's looking really smart, good job on it.

 

[Cuthy246]

It's looking really smart, good job on it.

Thanks, still a fair bit left to do but feels like it is getting there now.

 

[Cuthy246]

Kitchen unit progressing nicely now. Got the water and gas plumbed in. Also made a gas safe for the bottle.

 

[Cuthy246]

Just one suggestion Cuthy, make sure your gas locker is vented to the outside of the vehicle.

It is, big hole under the middle of gas bottle. It is a requirement to have the safe vented for an installation that can be accessed from the inside of the van.

 

[Melvyn Best]

Looking at the state of the gear oil I would be checking the scuttle drains are not dumping rain water onto the top of the gearbox which allows water in. It’s a common problem on Peugeot Boxers amongst others , I know the Diamond of Doom has problems with water around the injectors

 

[Cuthy246]

Looking at the state of the gear oil I would be checking the scuttle drains are not dumping rain water onto the top of the gearbox which allows water in. It’s a common problem on Peugeot Boxers amongst others , I know the Diamond of Doom has problems with water around the injectors

Indeed they do! Injector 1 looks rough as. Think the issue with the water was the vent pipe. It was dangling loose so the cap was collecting water rather than keeping it out (think upside down umbrella)

 

[Cuthy246]

Well we have had the first few outings in the van. Still needs a fair bit doing before it's finished but is usable as is. Just arrived back from Ben Hope, spectacular hike and a lovely spot to stop for the night

 

[Cuthy246]

Overdue a van update. Spent most of today wood butchering. Shelf unit, doors and drawers all hand made. The gap above the right hand side is where the table will be stored. One more drawer to do tomorrow then onto vanity items like vinyl flooring and refreshing the trim in the cab.

 

[DanZac]

How wide is the master? Is your bed long enough for a 6ft bean pole to stretch out in?

I've got a LWB Vivaro that I converted with a rock and roll bed / sofa, but when the time comes to upgrade a fixed bed across the van would be a better option if its wide enough.