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D3 camper conversion...
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Carpet down, chuffed with it so far. Thumbs Up

Next up will be the frame for the kitchen and rear storage unit.

Click image to enlarge


Click image to enlarge


Click image to enlarge
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #23579747th Jan 2024 3:15 pm
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gstuart
 


Member Since: 21 Oct 2016
Location: kent
Posts: 13685

United Kingdom 2005 Discovery 3 TDV6 Base 7 Seat Auto Java BlackDiscovery 3

Massive respect to u, , great idea with regards to the cardboard template

Huge credit to u for such a sterling job, following with interest and thks again for sharing


Bow down Bow down
   
Post #23580007th Jan 2024 4:51 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Only a bit of progress today, had an hour or so free this afternoon. Got the basic shape of the kitchen in place. Next up the other side made of ply, with some kind of wood-effect furniture board for the front panel and doors.

Also haven't yet made my mind up for the worktop material. Question

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Click image to enlarge


Click image to enlarge
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #235934718th Jan 2024 6:04 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

FYI on the fixings, I've used screws into the edge of the ply which isn't overly good practice because it risks splitting the ply layers. However I drilled decent sized pilot holes and in any event the screws are mostly just holding them in place whilst the glue dries on the several 8mm dowels I used on the join. Once dry, it'll be suitably strong, especially when the front panel and worktop create a glued-up box.

Ideally I'd have used a nail gun with some brads just to hold it whilst the glue sets, but a nail gun is on the shopping list still...
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #235935318th Jan 2024 6:36 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Little by little...

I've been working this weekend so have had next to no time to progress this, but merely on principle I managed to squeeze in about 15 mins of 'shed time'.

The opposite side panel in place, needed a little fettling around the wheel arch.

Click image to enlarge


Next up is the front panel and the worktop. I might stick to Ply, painted, for the front panel but equally I'm thinking of some laminate furniture board. 🤔

For the worktop, do I go Oak block or something easier to maintain like a 20mm kitchen worktop laminate?
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #23609564th Feb 2024 5:51 pm
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riverblanche
 


Member Since: 31 Aug 2010
Location: retford'ish
Posts: 2210

England 2008 Discovery 3 TDV6 HSE Auto Java BlackDiscovery 3

Hi,

for worktop in my camper I will be going with the lightweight core worktops specific for campers,

I have just tried to lift our solid oak island unit top in our house kitchen and the weight Rolling Eyes

so for the camper I'm going light weight Laughing a 1.8m is about £150

Thumbs Up
 Transit! 2019
Gone D3 HSE 2008
Another Porsche Cayenne 2022
Gone Porsche Cayenne 2020
Gone RRS HSE Dynamic 2016
Gone RRS HSE LUX 2011
Gone RRS HSE 2006
Gone D3 SE 2.7 2008
gone D2 Td5 1999

I plan on living forever and so far so good !

Club DG Mclaren stuff
 
Post #23610034th Feb 2024 8:41 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

A bit more progress today, I've cut and put on the front panel and cut the space where the doors are going to go.

Click image to enlarge


For the worktop I've used 20mm Beech, it's lighter than Oak and will come up beautifully with some oil, stain or varnish on them. I've split the top into two hinged sections (plus a small third fixed piece) so that I can hide the stove and cooking implements, which I've decided will be loose items rather than inbuilt, on a hidden internal shelf.

I've designed it so that the two hinged leaves can fold 180º so that if I want to, I can cook outside standing at the nearside passenger door. I need to work out some kind of hinged support to enable some weight to be put on that when folded out.

Click image to enlarge


Click image to enlarge


Next up is a shelf to go in the unit, and the doors of course. Then some paint.
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #236169911th Feb 2024 3:12 pm
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gstuart
 


Member Since: 21 Oct 2016
Location: kent
Posts: 13685

United Kingdom 2005 Discovery 3 TDV6 Base 7 Seat Auto Java BlackDiscovery 3

That’s really coming along mate , awesome way you’ve done the box structure unit

Thks again for sharing the progress, as it’s very impressive and indeed as u also mention should come up a treat once treated , will u use something like yacht varnish with its hard surface plse

Following with great interest Bow down
   
Post #236175311th Feb 2024 9:53 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Thanks for the encouragement, I'm pleased with it so far and really enjoying building it.

I've just spent a couple of hours this evening giving it two coats of grey on the outside, two coats of white on the inside. On the top I've just used a generic clear satin wood varnish as that's all I had in the shed. It's come up alright, but it doesn't have a deep shine. You're right about yacht varnish, I reckon that would give a beautiful and hard-wearing surface.

Click image to enlarge
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #236177011th Feb 2024 11:24 pm
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Moo
D3 Decade 


Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13967

Ukraine 2005 Discovery 3 TDV6 S Manual Zambezi SilverDiscovery 3

Nice Thumbs Up Just wondering if a pull out unit from the rear might have given easier access? Confused
 New Defender L663 110 SE (known as Noddy!)

Sold Volvo XC90 R-Design (known as Basil)

Sold - D4 HSE (Known as Gerty)

No longer the Old Buses original owner Sad
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control 
 
Post #236177511th Feb 2024 11:44 pm
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DIY Ace
 


Member Since: 06 Feb 2019
Location: Hampshire
Posts: 900

United Kingdom 2005 Discovery 3 TDV6 HSE Auto Bonatti GreyDiscovery 3

Quite possibly Moo. I will be building a rear unit too, which will house the mattress, clothes, few tools and portable battery thing.

I've done it this way as I'm keen to be able to use the kitchen area from within the car, rather than just outside from the boot end, so this internal setup seems the best option.
 2022 BMW i4 M50. Bought Oct 2022. 10,200 miles and counting...
2014 BMW 435d convertible. Bought July 2021. 58,000 miles and counting...
2005 Discovery 3 HSE Auto. Bought Feb 2019. 169,000 miles and counting...
2009 Freelander 2 XS Manual. Bought Sep 2013. SOLD Aug 2021 (already regretted!)

https://youtube.com/channel/UCO_u_0D45x9KGfiNstzLJnw 
 
Post #236177711th Feb 2024 11:49 pm
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Moo
D3 Decade 


Member Since: 13 Aug 2010
Location: Wiltshire
Posts: 13967

Ukraine 2005 Discovery 3 TDV6 S Manual Zambezi SilverDiscovery 3

Thumbs Up

Look forward to following the journey... Thumbs Up
 New Defender L663 110 SE (known as Noddy!)

Sold Volvo XC90 R-Design (known as Basil)

Sold - D4 HSE (Known as Gerty)

No longer the Old Buses original owner Sad
231,000 miles and counting
05 S manual owned from March 2005
D4 Face lifted
Still original injectors and turbo
V8 Front brakes
BAS Remap, Allisport Intercooler and deCat
EGRs blanked
T-Max split charge
Hanibal Expeedition rack
Prospeed ladder
Duratrac tyres
IID BT
BAS FBH control 
 
Post #236177912th Feb 2024 12:00 am
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gstuart
 


Member Since: 21 Oct 2016
Location: kent
Posts: 13685

United Kingdom 2005 Discovery 3 TDV6 Base 7 Seat Auto Java BlackDiscovery 3

DIY Ace wrote:
Thanks for the encouragement, I'm pleased with it so far and really enjoying building it.

I've just spent a couple of hours this evening giving it two coats of grey on the outside, two coats of white on the inside. On the top I've just used a generic clear satin wood varnish as that's all I had in the shed. It's come up alright, but it doesn't have a deep shine. You're right about yacht varnish, I reckon that would give a beautiful and hard-wearing surface.

Click image to enlarge


Ur so welcome as it’s justly deserved of how nice that looks

Glad u like the idea of the yacht varnish , i used it on a few doors upstairs on my old house, sprayed on 4-5 thin coats and came up extremely nice giving it a deep gloss along with being very hard wearing

Lightly sanded in between each coat to just remove any imperfections , hope that’s also useful to u

Wonder if a clear lacquer sprayed over the white or grey may also provide some extra precaution from any damp etc , suppose the only worry is if the lacquer reacted to the existing paint ??

Really enjoying the thread with great interest and once again many thks for sharing it with us 👍
   
Post #236178112th Feb 2024 3:03 am
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NewDevon4rmy
 


Member Since: 14 Apr 2023
Location: in your rear view mirror
Posts: 18

United Kingdom 

Looking good!
 Current: D4 TDV HSE
Recently: CR-V Gen 2
Formerly: LR3 V8 HSE 
 
Post #236184712th Feb 2024 6:55 pm
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Unknownmanxman
 


Member Since: 28 Jan 2024
Location: Isle of Man
Posts: 4

2011 Discovery 4 5.0 V8 HSE Auto Ipanema SandDiscovery 4

Very Happy Looks really good
  
Post #236197913th Feb 2024 11:36 pm
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