We are building a library of campervan maintenance and campervan upgrade know how videos where we share technical advice and demonstrate installations. These videos are designed to help you undertake your own campervan maintenance, upgrades and campervan builds.

Peugeot Boxer L2H2 Campervan Conversion Is Finished.

This is the last vlog in the series of converting the Peugeot Boxer L2H2 to a campervan. The conversion is now complete and the campervan is now on it’s first tour across the UK, Ireland and Austria. We will get the van back next year to install a roof decking and finish boxing in the Truma D4E boiler.

This video captures an overview of the exterior and interior, starting with the initial design using Vanspace3D software compared to the finalised exterior and interior layout.

There is an overview of the Victron and FogstarDrift electronics systems and the Truma D4E installation. All of these subsystems are working really well. This has been a very enjoyable design and build.

Peugeot Boxer L2H2 Campervan Conversion Finishing the Interior and Exterior.

We are up against time now, working to finish the campervan for its first tour. This video captures the final finishes to the interior comprising building the cupboards and doors. Boxing in the hot air ducting, fitting the window blinds and plywood sheeting the interior doors. On the exterior, we fit new tyres to all four wheels, paint the wheels black and fit wheel trims. The tyres were legal but quite worn so we decided to replace them and repaint the rust wheels. Finally a decal is added to each side of the van to set it off.

Boxer Conversion L2H2 Campervan Conversion Fully Functioning Electronics and Truma D4E Installation

This video captures completion of all of the electronics with everything fully functioning – all 12V circuits, 230V circuits, Victron SmartSolar controller, Victron Smart Orion dc-dc controller, Victron Multiplus Inverter with bluetooth dongle and Fogstart Drift Lithium 280Ah leisure battery. Installation of a Truma D4E is then captured in some detail – spanning installation of the boiler, the flue, the controller, hot air ducting and plumbing the diesel pump fuel line into the van sender unit.

Boxer Conversion L2H2: Kitchen, Gas & Water Plumbing and Seat Base Storage Apologies for the delay in publishing more videos of the Peugeot Boxer conversion. We took a break for our summer tour and have been under progressive time pressure with the Boxer since we returned, so this has been the delay in editing the videos. I now have a series of videos in editing and these will be published in a more timely manner.

This video captures some finishing off of the kitchen/shower along with gas plumbing to the cooker and plumbing of the water pump and accumulator. Then there is the completion of the two seat bases which form the two facing seats and a pull-out single bed – in addition to the double fixed bed.

Boxer Conversion L2H2 12V & 230V Electrics and Water & Gas Plumbing This video captures a little 12V and 23OV wiring in the garage area, water plumbing and has plumbing. I’m mounting a 12V socket and 230V socket in the garage and wiring these to the 12V fusebox and the Victron Multiplus II respectively. Then I plumbing cold and hot water to the kitchen tap and installing a water filter to the kitchen tap. I plumbed the water filter twice because I wasn’t happy with the initial location. I then mounted and plumbed the combined water pump and accumulator damper. Thereafter I built the gas locker for the 6kg Propane cylinder, drilled the gas drop through the van floor and installed this in its location. Inside the gas locker consists of four cylinder locating fee, the strap assembly, the Propane regulator and the flexi metal gas pipe from the cylinder to the regulator inlet. This is a lot to fit into the garage length of an L2H2 so I needed to plan carefully.

We are now taking a short break from the Boxer conversion build to go on our European summer tour in our own campervan.

You can follow our tour at www.mcnaughtsontour.com

We will continue the Boxer conversion when we return.

Boxer Conversion L2H2 Building Seat Bases and Single Bed. We build the seat bases whilst the Boxer van is in the garage for a routine timing belt and water pump change. One seat base is straightforward whilst the other requires quite a lot of extra work. The design in VanSpace3D is accurate, but I had not taken the pillar dimension into account. It all works out well in the end. We now have two seat bases with storage below and the option to have a single bed, in addition to the fixed double bed.

Boxer Conversion L2H2 The Interior Is Taking Shape. Work is progressing on converting the Boxer L2H2 and the interior is now starting to take shape. The shower cubicle is complete and plumbed in (still to be sealed) and the kitchen is now largely built, with a little wiring, plumbing hook-up and a couple of shelves to be finished off.

Boxer Conversion L2H2 : Building The Interior 3. The shower cubicle is lined in plastic sheet in this video and the cavity under the cab shelf is insulated and then closed in with plywood. That’s all the prep relating to the shower cubicle so I then fit the mixer tap, plumb hot and cold water lines and run the shower waste hose to the waste water tank. At the same time I run a waste hose for the sink to the waste tank and run a hose from the fresh water tank outlet to the garage location where I plan to fit the water pump. I complete some planning sitting the fridge, cooker and kitchen sink in place to confirm details and spacing.

Boxer Conversion: Building The Interior 2. We continue to build the interior. In this video we are cladding the roof and fitting downlighters, then building a shower cubicle and building a platform for the shower tray. Whilst we were doing this we insulated above the cab as it will be difficult to access this once the shower cubicle is in place. We’ve order plastic sheeting to line the shower cubicle and some plumbing materials so once these arrive we’ll line the cubicle and plumb everything in.

Boxer Conversion: Building The Interior. We are starting to sheet the walls in this video and finish the bed frame and slats. As we do so, all of the wiring which will be located behind the walls or in a cavity is being enclosed in split conduit. Once this is done we have build a structure under the garage which will house the battery and all of the electrical/electronics modules and components.

Boxer Conversion: Fitting CAK Underslung Water Tanks. In this video I am fitting CAK underslung water tanks to an L2H2 Boxer. I bought the tanks from leisurelines.net and the guys there were helpful with their advice. I was originally looking at the 66 litre fresh water tank and they advised some customers reported this did not fit an L2H2. They advised if this was my experience then they will swap if for a 50 litre tank. I measured under the van and opted for the 50 litre tank. This was the correct decision as the handbrake assembly would need modified to accommodate the longer 66 litre tank on an L2H2 van. The installation process is quite straightforward. I did need to drill some holes in a crossmember to locate the hook on the hangers to mount the tanks to the chassis. I bought the CBE water level gauge and level sensors from leisurelines.net at the same time as the tanks and the guys fitted these to the tanks before they shipped them to me.

Boxer Conversion: Fitting Hartford Turbo Roof Vent. This video captures the installation of a Hartford Turbo Roof Vent, a roof mounted vent with an integrated two-way fan. The location of the roof vent is particularly important on this installation as I am trying to install it as near as possible to a roof bar which is not yet mounted and to provide maximum remaining space behind the roof vent for the future installation of some decking. It’s a bit of a judgement call to have the roof vent close to the estimated position of the roof bar whilst still leaving enough space for it to open fully. The Hartford roof vent and ridged adapter plate were purchased from Magnum Motorhomes.

oxer Conversion: Solar Panel Installation and 12V Harness completed. The cable runs for the 12V wiring harness are now completed and mounted in split conduit through the walls and rectangular conduit on the garage floor. The second task in this video is to mount twin feedthroughs on the roof and mount the Victron Energy solar panel over these.

Boxer Conversion: 12V Harness and EHU Bulkhead Socket. I am continuing to run the electrical cables in parallel with some other tasks, including deciding upon the solar panel location, the location of the decking & roof vent and fitting the EHU bulkhead socket.

Boxer Conversion: Building the fixed bed frame, running more cables and locating the shower tray. As I continued to run some electrical cables I wanted to know exactly where the front of the fixed bed would be to create a neat cable installation, so we built the fixed bed frame first. Then we located the shower tray so I could check the length between it and the bed and confirm the design for the kitchen.

Boxer Conversion: Fitting windows and flooring. We are fitting two aluminium framed double glazed windows, one in the rear right door and one in the sliding door. This is a job that requires confidence, and quadruple checking measurements, as you don’t want to cut a hole that’s too big for the windows. Otherwise it’s relatively straightforward. The actual fitting of the windows to the door is a two person job, with one person on the outside applying even pressure to the window frame and the other inside the van fitting the wooden frame and screwing the two parts of the window together to compress the whole assembly against the door and the sealant.

Boxer Conversion marking out windows, running electrical cables and laying flooring: This is next phase of the Peugeot Boxer conversion. We are marking out windows in the sliding door and rear door in preparation for cutting out the metal work. We are also running electrical cables and conduit whilst we await the Sikaflex sealant arriving, before we can cut out the windows. In parallel, we are planning the locations of the electronic modules and the heating modules using vanspace3D.

We are finding this software very useful.

Peugeot Boxer Conversion Wall Insulation and Planning the Electrical Cable Runs: In this video we complete sealing the floor insulation, refit the plywood flooring and insulate all of the wall cavities. We’ve left some areas for now where we plan to fit windows and a roof fan.

All of the van electrical cables runs have been traced so we know where these are and we’ve been planning the routes to run the cables for the conversion. We bought the windows but a combination of a late delivery from Amazon of the sealant and rain stopped us progressing this for now.

On the upside, whilst it’s still cold outside the temperature inside the van is noticeably warmer.

Peugeot Boxer Conversion Floor Insulation and Sound Deadening: It’s been a busy couple of weeks on other jobs. Also visited the motorhome show, had 4 days away in the campervan and prepped the Caddy Maxi campervan for its MOT. As a result, progress with the Boxer is a little slower than planned. The floor is now insulated and the plywood floor sanded. All of the walls and roof are now sound deadened, leaving some locations for windows.

Peugeot Boxer Conversion Strip Out and Inspection: This is the start of converting a Peugeot Boxer. Starting with stripping out, cleaning and inspecting everything in parallel with creating a draft design with vanspace3D software and creating the initial parts list. This conversion will be completed in the evenings and weekends.

Campervan Maintenance. Mirror Ambient Temperature Sensor Replacement. The dashboard hasn’t been displaying the ambient temperature recently. I find this annoying so decided to replace the temperature sensor which is located in the driver mirror body.
I’ve read the van can use the temperature from this sensor during a DPF regen and for the air conditioning. I’m not sure if this is the case, but I don’t like to have things not working correctly, so I am replacing the sensor.

Campervan Maintenance. Victron Shunt Installation and Set Up: Installing the Victron smart shunt, configuring the settings and testing the electrical system with different loads. The shunt is a straightforward electrical installation and provides extremely useful functionality.

Campervan Maintenance. Resolving P2563 Turbocharger TC boost control position sensor error: A new fault developed on the first test drive after replacing injector 2 and the four glow plugs. I feared an expensive repair and this video captures the fix.

Campervan Upgrade. Installing a Victron Charger and Ground Busbar: I am upgrading the Sargent 12V charger to a Victron charger to benefit from multi-stage charging and access to the charge data. Whilst there, I am upgrading the ground (0V) battery wiring by tidying it up and fitting a ground busbar.

Campervan Upgrade. Replacing the shower mixer tap: Tracing a water leak from the shower and discovering this is a bigger job than I thought. Whilst there, after replacing the mixer tap, I modified the plumbing to make it easier to maintain.

Campervan Maintenance. Replacing the air conditioning condenser: In the previous video, when Logan Vehicle Services were replacing the glow plugs I noticed the air conditioning condenser was in poor condition. We noticed when we were in Italy in the summer the air conditioning wasn’t as cold. Now we know why.

Campervan Maintenance. Fixing P0683 Comms glow plug control error: When the AA diagnosed a faulty injector 2 they also diagnosed fault code P0683 Comms error glow plug control error. So when Logan Vehicle Services were replacing injector 2 they investigated the glow plug fault and I decided to replace all four glow plugs. The wiring harness was also in poor condition so this was replaced at the same time. It may not have been necessary to replace all of the glow plugs, but it’s a fair amount of labour to strip down the front end of the van to gain access so I thought this was best. I also replaced the van battery at this time.

Campervan Upgrade: The standard Dometic three-way fridge has been temperamental. It does work, but it is sensitive to unlevelness so decided to upgrade to a compressor fridge, powered by 12V/24V dc only.

This is the first phase of the upgrade, so dual battery upgrades will follow.

This video also captures upgrades to the bed supports and fitting the rear window blinds Wendy has made.

Campervan Upgrade: This video captures the conversion of the central glovebox to a double drinks holder, installing the Fiat OEM parts.

The parts are available on Amazon at https://amzn.to/47f8eLz

Campervan Maintenance: The garage advised our tyres were near the limit which I could not understand as I had measured their depth the day before. This experience resulted in new tools, new tyres and new rear discs.

Then new locking wheel nuts. Now the van is ready for summer touring!

Campervan Upgrade: Installing a Pioneer SPH-DA360DAB multi-media radio replacing the original Fiat radio.

There is a fair amount of work to do and this requires some planning. There is a need to cut out space inside the dashboard to accommodate the larger radio. The Blue & Me module also needs relocated inside the dashboard.

I bought the Pioneer SPH-DA360DAB from Dynamic Sounds. The people there were very helpful in advising the product to fit my van.

Campervan Upgrade: Upgrading the front suspension to replace the McPherson struts, the springs, the top bearing mounts and the drop links. This job was too big for me so I asked Raymond at RS Autos if he would do it and I could help and video the job as we went.

We fitted replacement Monroe McPherson struts and SACHS springs.

Campervan Upgrade: Upgrading Volkswagen Caddy Maxi fitting roofbars and a bike rack.

The roof bars are supplied from DST Automotive, this version is called Can Auto Turtle.

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