Conversion Corner: A divine creation

By Malcolm Street

Motorhomes come in all shapes and sizes – everything from super length 40-footers to pop-top campervans – and budgets. But what happens if your taste runs to a 40ft motorhome but your budget is better suited to a pop-top campervan?

One solution is a DIY job. That, of course, has inherent complications: you have to be mechanically competent; you have to have a certain amount of vision and the will to carry out your vision, and you need a great deal of patience. Murphy’s Law unequivocally states that if things can go wrong, they will. You will need great deal of persistence as everything will probably take about twice as long as you thought. Finally, your budget should have a certain amount of ‘rainy day’ money in it.

Great beginnings

Erik and Ellen O’Dempsey are a couple who probably have most of those characteristics. Well, I assume so, because their motorhome Ichthys went from an idle dream to reality – but not without a bit of sweat along the way.

Erik and Ellen started to think about their retirement motorhome back in 1996. Some of their friends thought them a little strange but newly-met acquaintances in the Campervan and Motorhome Club (CMCA) knew they were onto a good thing.

In May 1998 Erik and Ellen made their first big step by purchasing a 40ft tri-axle Domino coach. It was a truly wonderful purchase, except the integrated air-conditioning didn’t work, the motor didn’t work, the brakes didn’t work and the existing floor was very dodgy…

For the next couple of years, Erik and Ellen didn’t do too much about their prospective motorhome, except consider layout plans. Erik still had his tree surgery business to run and the motorhome was really on the back burner. But following a serious road accident, from which Erik emerged relatively unscathed, the motorhome ball began rolling again. “You only live once” was the thought, so Erik sold his business and motorhome conversion started in earnest.

Hard yakka

The first step was to do something about the dud motor. The original 350hp GM diesel was replaced with a reconditioned 475hp GM unit. Once that was up and running (not without a few dramas) the next step was to find somewhere to do the conversion work.

Erik and Ellen eventually opted for a former army battalion workshop site, which housed a huge wartime-style Nissen hut. Not only large enough to take their pride and joy along with a workshop area, it was also big enough to give the O’Dempseys some temporary accommodation, ie, a caravan, while they worked on their dream. It was while moving their dream motorhome to its new temporary abode that Erik discovered the brakes weren’t exactly working properly... still, they arrived safely and work began in earnest.

The first chore, in about June 2001, was to strip the coach of most of its original fittings, including the windows. This was the first time I laid eyes on the O’Dempseys’ dream. It was difficult to envision the final product while looking at that old coach body, sans windows, sans seats, sans wheels, sans just about everything, while Erik explaining his vision – raising the roof, two slide-outs, new floor, huge kitchen, solid timber bench tops and leather seats.

In more recent times, the O’Dempseys’ dream has become reality. It did take somewhat longer than the original schedule but Ichthys is just about ready to hit the road for a trip around Australia.

A real beauty

What emerged from that old coach was an impressive 40ft motorhome. The roof has been raised 500mm and fully insulated with an Insulpro membrane. Everything mechanical has been refurbished, repaired or replaced, all rusty steel framework has been repaired or replaced, and a new floor and two slide-outs have been installed. One 3.6m x 0.8m slide-out expands the lounge while the other, 2.4m x 0.6m, opens up the rear bedroom.

Some things had to be bought new, of course, but other items were purchased cheaply or for nothing. For instance, the T4 grade aluminium external cladding, bought as surplus to RAAF requirements, was previously destined for a Nomad aircraft. The styrene foam used for insulation had a previous life as packing material at a large company.

In the not-seen-very-often category was the work below floor level. Stainless steel water tanks, 1000 litre fresh, 750 litre grey and 250 litre black were installed. Much work was done with metres of electrical wiring, plumbing and gas pipes, including two 18kg gas cylinders. 2200 amp hours of batteries supply, with the 12V load backed up by both solar panels and a 6.8kVA generator. In addition to general storage lockers, a large slide-out barbecue and full freezer are in situ.

Outside the motorhome, there are not one but three awnings. Two are on the nearside, one above the barbecue and the other above the entry door, with the third on the offside attached to the slide-out. The external lighting is interesting: the grab handle light is actually on the door and the other external lighting consists of old-style hurricane lamps that have been ‘electrified’ and sit on detachable arms around the barbecue area.

Internal style

The floor is all laid in Tasmanian oak. In the rear of Ichthys is a large bedroom beside which is a full bathroom with separate shower, Vacuflush toilet and vanity sink.

Mid-motorhome is a huge kitchen. Ellen loves to cook and the kitchen has been designed accordingly with a commercial gas stove plus one of the largest slide-out pantries I have ever seen. Slightly unusual are the solid (I mean solid) timber polished benchtops. Made from a tree that Erik personally cut down, they are an impressive sight.

At the front of the motorhome, complete with leather seats, is a very comfortable lounge area and a proper dining table – not just a dinette. Although Erik did most of the mechanical work, Ellen, a keen craftswoman, has completed much of the interior work including the upholstery, timber work and the lead-lined windows installed in various places.

You might notice that there are a few clocks around Ichthys: Erik collects them. Sadly, his entire collection of 200 or so won’t fit, so a token amount is kept on board. One of the clocks is an early 1900s bundy work clock; but I suspect that won’t get much use on the road.

And, just in case you are wondering, Ichthys is a Greek word, an acronym that is represented by the fish symbol used people of Christian faith, like the O’Dempseys.

Life on the road

Having just about completed their motorhome and shortly, the matching attendant trailer, Erik and Ellen hope to be in Perth at the end of this year but will detour via the CMCA rally at Maryborough, Qld.

Along the way, the couple will be doing some voluntary work for the Anglican Bush Church Aid Society at some of its remote bush centres. Ellen is also keen to teach some of her craft skills at events run by organisations such as the Country Women’s Association.

DIY your own motorhome? No problem: but make sure in addition to the necessary mechanical and craft skills you have plenty of patience, persistence and time. I am sure Erik and Ellen O’Dempsey will attest to this.

Also, anyone contemplating building their own campervan or motorhome should ensure that they fully understand the relevant regulations, not only for the vehicle itself but also for electrical and gas systems.

All the necessary certification should be obtained as installation work proceeds.