2001 Sprinter 411 build from scrap Murvi Morello!

[Mickandsej]

Hi all
Recently I was given a 1992 Fiat Ducato Maxi LWB hi top Murvi Morello. It was a resto project but the interior layout is fantastic, in fact it’s been in unchanged continuous manufacture for over 30 years now on different base vehicles.
However on full examination the shell was too far gone to restore with the interior in it as the gutter rails, arches and sills all needed welding in carpeted, furnished or wiring loom areas.
So I searched hi and low for a new base vehicle, after two aborted purchases of a 2004 Boxer and a 2005 LDV convoy - both of which were a day away - a last search of gumtree threw up a 2002 Sprinter 413 CDi factory minibus. Owned from new by Henley College, with just 12000km/75k miles and Rygor service history - and no seats left in to mess around selling - and it was 4 miles from home!
So I’ve started the strip down, and still running my Previa micro camper until it’s all done.
Once the Fiat has gone I can start working on the Merc on the drive at my own leisure.
Happy days ahead!

 

[Sandbagsid]

great hope it all goes smoothly for you will look forward to photos as you progress.

 

[egg-fried-rice]

Keep us updated (we love images).

 

[Mickandsej]

Will do!
So far the strip down has gone really well. The Murvi was so well made in the first place, good solid framework, loads of reusable trimmed plywood, miles and miles of quality wiring, all the Propex, Cascade stuff is coming out in good order. I’m not going to re use the loom as is but the wiring will save me £££s. It also has a good 240v ring main installed which again is reusable, with a new consumer unit and charging system as the original transformer unit looks a big heavy brute (though it works perfectly).
First phase is to finish the Fiat then sell it swiftly. It’s a very rare base - I can’t find a trace of them - LWB factory hi top with full height barn doors and a 3.5 ton chassis. It’s definitely restorable and much easier to do when it’s empty. So far the sills look very good from inside the van, it’s really only the outers that are shot.

 

[Mickandsej]

Well I’ve sold the Ducato after a major strip down! Got everything out in one piece even the shower tray. It’s all been thrown into the Merc, the shed, the garage and probably the spare room….
But whilst I’ve been trawling for a sticker set for a dark blue van, it’s just dawned on me that as a 4.6t van I won’t gain any speed improvement - 50/60/70 vs 60/70/70 under 3.5t. As I’m paying £165 tax I don’t think it’s worth doing. I’ve insured as a self build with no time limit so I’ll just carry on as is…

 

[Mickandsej]

Oh and I’ve still got a 62mph limited fitted anyway!

 

[Mickandsej]

Blank canvas, started sketching it out on the van floor. Going to put inboard fresh water, trying to get all gas and water on the offside of the van, and all electrics on the near side. Might have to put in separate bottle for the hob as I’m hoping to go full electric later on. Won’t be fitting the fridge back on gas, early plan is to go 200w solar on the roof and run each appliance on its own inverter from a leisure battery bank. Might have to gas the water heater for now.
Going to book an early mot in the next week or so so all that worry is done, followed by starting the sound deadening and insulation, and moving the sliding windows to the middle & blanking the osr window.
I’ve got around 1000mm of extra length in the Sprinter so I can be very imaginative whilst keeping to the Morello layout which is perfect for us.

 

[Mickandsej]

MOT passed, just needed rear ARB links! Will do the nsf inner rack joint soon as it’s been an advisory for the last 4yrs/1800km.
Bits arriving every day: 200W solar kit, tint film, workshop manual, self contained 8kw diesel heater, rear seats removed pending modification, etc.
Mrs hit the roof when she saw this lot in the spare room yesterday….

 

[Mickandsej]

Going for rigid solar on the roof, also now leaving the windows where they are as I can’t get roof vents at the back for the kitchen and WC, so will work around the sliding windows.

 

[Mickandsej]

By the way has anyone any experience of these inverters? A lot of kit for £269.99

 

[egg-fried-rice]

By the way has anyone any experience of these inverters? A lot of kit for £269.99

That’s a lot of power. Not used it myself, its far too much for what I need. The higher the wattage the more they consume on standby. Would be interesting to see what it can run and the battery size set-up.

 

[mrmoosehead]

That’s a lot of power. Not used it myself, its far too much for what I need. The higher the wattage the more they consume on standby. Would be interesting to see what it can run and the battery size set-up.

It'll only consume power on standby if connected if i put an inverter in, most of the time, it'll be switched off

 

[Mickandsej]

Thanks for your replies, I think you’ve answered my concerns. It’s probably overkill for my needs.
I was looking at it for going gas free later on, but I’m not building a full off grid van, we only do one or two trips a year (festivals) off grid and the rest of the time will posh it at CMC (etc) sites. It was a case of seeing how I could delete some of the gas from the build by switching to electric for water and heating. Have gone diesel for heat and I think my solar set up will be man enough for the fridge with/without an inverter. Could always fit an induction hob later on for hook up sites and Halfords mini hob other times..

 

[Mickandsej]

Pleasant discovery today, the upper walls are carpet clad aluminium sheet so that will add a layer of insulation in combo with the fleece, liner and dead mat. Nicely riveted in I’ll remove them, add batten for the cabinet hanging, and re fit. Roof as expected is ply so good news again!

 

[Mickandsej]

I have an ongoing issue searching for a replacement roof vent, it’s a non standard size of roughly 360 f-r and 420 width. Because I’ve got a ridged roof I can’t fit a 500x500 and 40x40 is too small. It’s a bit sun worn and getting brittle so I’d like to swap it out whilst I’m working on the roof.
Last ditch fix would be to crush the ridges flat but it’s not an ideal solution…

 

[mrmoosehead]

You can fill between the ridges to make a level surface.
I had to do that for my micro heki.
I solvent welded 3mm pvc sheet together to the right height, then chamfered the edges to fit the ridge profile, then sealed it in well.
Some people use pvc moulded skirting

 

[Mickandsej]

Not sure what I’ve got in the shed but I thought it might come down to a little Sikaflex engineering! Once you pop the tube it’s all got to go so might as well do that then - cheers for the tip

 

[Mickandsej]

500 would be nice as it would flood the van with light.

 

[egg-fried-rice]

You can fill between the ridges to make a level surface.
I had to do that for my micro heki.
I solvent welded 3mm pvc sheet together to the right height, then chamfered the edges to fit the ridge profile, then sealed it in well.
Some people use pvc moulded skirting

I did similar to you but used layered mastic. There’s now a company that makes the Ridge Inserts, (not sure if they fit most vans) they should be available on EBay Search “1 Pair Filling Profile Roof Vent Fiat Ducato Citroen Relay Peugeot Boxer Camper”

 

[Mickandsej]

I’m taking all this on board, I’ve set aside a weekend to do this - weather permitting. I’ve gone for 2x400 and 2x280. I decided it was easier to add strips to the side of the existing front hatch hole than ridge all four sides fitting two 500s. Each one will be a different install but each will only have one edge that needs ridging, I’ll pack up the other three sides with some upvc moulding strips.
I looked on YouTube for fitting videos and I was pretty horrified at them all - they were basically how NOT to do it! One video showed it being stuck on with multiple layers of bath mastic from a roll. Not sure how that would cope with the summer sun… another one was fitting them after the insulation and wasted loads of dead mat, and even had loose bubble wrap floating under the roof skin. Surely that’s a huge condensation risk later on….