Restorations, Rebuilds & Projects. Restoring her to Concourse? Just getting her running again? Or got a mad project? This is your room.

Focus St van conversion project

Thread Tools
 
Search this Thread
 
Old 22-05-2015, 08:22 PM
  #1  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default Focus St van conversion project

I have been trawling the Internet in a desperate search for a focus van with no luck... Rocking horse...
So I'm building one!
Is anyone else out there embarking on the same quest or has anyone done it before?
I'm surprised fords only made them for Ireland!
It's a focus, mark 2, 3 door (that was hard enough to find!!) 2.0L petrol titanium. Be great to get a discussion going and I'll post photos along the way
Old 22-05-2015, 08:23 PM
  #2  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default Photos to date




Old 23-05-2015, 10:09 PM
  #3  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default Day 2 rear stripped!




Before....





After...
Old 23-05-2015, 10:12 PM
  #4  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default Airbag disconnection

As I'm converting to a van... I no longer need the side rear airbags.
I have disconnected them now but the light is on on the dashboard... Does anyone know how to loose this completely and but maintain the front airbags 100% surely the rear part of the airbag circuit can just be removed?
Old 23-05-2015, 11:18 PM
  #5  
mk1turboestate
Advanced PassionFord User
iTrader: (2)
 
mk1turboestate's Avatar
 
Join Date: Dec 2010
Location: manchester
Posts: 1,844
Received 73 Likes on 68 Posts
Default

Not sure about the airbags,
Also why are you doing this, I understand if it's an estate so can be used as a van but I can't see the point of this? Surely insurance is going to be an issue aswell
Old 23-05-2015, 11:19 PM
  #6  
botters
competant bodger
iTrader: (2)
 
botters's Avatar
 
Join Date: May 2009
Location: preston
Posts: 6,234
Received 23 Likes on 21 Posts
Default

find out what resistance the rear airbags create by being connected and simply replace them with resistors of the same level and the light will be out
Old 24-05-2015, 07:04 AM
  #7  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Thanks botters I was thinking about doing that but just wondered if it can be removed completely. But that sounds easy.
Old 24-05-2015, 07:08 AM
  #8  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by mk1turboestate
Not sure about the airbags,
Also why are you doing this, I understand if it's an estate so can be used as a van but I can't see the point of this? Surely insurance is going to be an issue aswell
Mk1turboestate
I'm doing this as I needed a smaller van.. But not too small like a fiesta
I Looked around at the usual connects and belingos etc and they are just basic and ugly.
Just fancied a project and fancied something different.
An estate would be too long plus everyone has done that one
Old 24-05-2015, 09:54 AM
  #9  
kyle_st200
PassionFord Regular
 
kyle_st200's Avatar
 
Join Date: Dec 2008
Location: Grantham
Posts: 404
Received 5 Likes on 5 Posts
Default

What are you doing about the side windows? I was after a van but really wanted rear seats so was looking at a mk4 astra. I didn't so much need the space as all my tools fitted in my fabia but just thought a van looks more professional. Ended up taking a corsa sri cdti in part ex on my octy vrs and thought I'd convert that to van. The metal van panels were Ł80 each then I'd need to spray them and have them fitted so instead got the windows vinyld and sign written.
Name:  E2930004-D4D7-43E6-A26C-E0A42FAFE2E3_zpspl7hs8jt.jpg
Views: 578
Size:  213.8 KB
Colour looks fine at this sort of angle but is slightly off side on
Name:  81D77125-E134-4EDB-8F48-09B3FBC0F936_zpsqz7bcgfy.jpg
Views: 569
Size:  124.0 KB
Think it cost Ł100-120 though so I'm not that bothered. Left it as a car so can still use it to take the kids in but looks like a van for work.
Old 24-05-2015, 02:07 PM
  #10  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Looks good
I want to get rid of the glass and either fit the focus van panels (but only available in Ireland) or weld them up.
But apparently the best solution will be to wrap them in 1mm alloy and bond them in over the glass.
I'm glad someone else has converted (kind of) a car into a van.
This was my inspiration (but the body shape isn't going to change..




Last edited by Projectdave; 24-05-2015 at 05:58 PM.
Old 24-05-2015, 06:10 PM
  #11  
kyle_st200
PassionFord Regular
 
kyle_st200's Avatar
 
Join Date: Dec 2008
Location: Grantham
Posts: 404
Received 5 Likes on 5 Posts
Default

Ideally I'd of put the metal van panels in but you can only get them from Vauxhall and it looked chavvy turning up at jobs in it so just for ease I had the windows vinyld and tinted the rear window so you couldn't see through.
I don't know how good of a finish you'd get cutting some 1mm metal I think the curve of the window would be too hard to get looking good?? If it can be done I'd do it to mine and have it sprayed as it does bug me the colour is off when I look at it side on. If you manage to sort this out let me know I'll look into it for mine
Old 24-05-2015, 06:15 PM
  #12  
kyle_st200
PassionFord Regular
 
kyle_st200's Avatar
 
Join Date: Dec 2008
Location: Grantham
Posts: 404
Received 5 Likes on 5 Posts
Default

Forgot to say I didn't want to try welding in a panel or something like that because I like the colour of the van and didn't want to spend out on a respray as to be honest it's not worth putting the money into. If need be I would just matte black it but to be honest I'm not keen on matte black and think it would look pretty shit hence the choice to vinyl.
Old 24-05-2015, 08:35 PM
  #13  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

I have a guy that builds security vehicles and armoured trucks so he reckons it'll be easy and won't cost much at all.
The 1mm alloy is thin enough to bond straight to the window, then it will still leave a recess which will have a sealer run around the edges to seam it to the quarter panel.. Then it'll be painted. Just before it goes in for paint I'll have it done and put on a photo.
Old 25-05-2015, 06:44 AM
  #14  
sridgett
The only way is dagenham
 
sridgett's Avatar
 
Join Date: Jan 2014
Location: France
Posts: 1,927
Received 57 Likes on 56 Posts
Default

Cool projet matey
Old 25-05-2015, 07:15 AM
  #15  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by sridgett
Cool projet matey
Well thank you 😜
But I haven't really started yet
Old 25-05-2015, 02:23 PM
  #16  
DAN@ADRIAN FLUX
Sponsor
 
DAN@ADRIAN FLUX's Avatar
 
Join Date: Oct 2013
Location: Norfolk UK
Posts: 257
Received 19 Likes on 17 Posts
Default

Hi,
If you need any help with insurance at all for this type of conversion then please feel free to drop me a line.
Regards,
Dan.
Old 25-05-2015, 07:05 PM
  #17  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Thanks Dan.. When I had my series two RS escort when I was younger I used you guys so I probably will be returning
Old 26-05-2015, 06:02 PM
  #18  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Anyone know the size of resistor needed to blank the rear side airbags off..? I've used a 2 ohm resistor but light is still on 😔
Old 26-05-2015, 07:01 PM
  #19  
RichieST
15K+ Super Poster!!
iTrader: (2)
 
RichieST's Avatar
 
Join Date: Aug 2004
Location: Wiltshire
Posts: 18,732
Received 449 Likes on 397 Posts
Default

Find out what resistance the airbags have then use the same resistor. You may find that the light will need to be turned off via diagnostics once it has come on.
Old 03-06-2015, 08:28 PM
  #20  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default St body kit or any (NON fast and furious) kits?!!

Looking for an St kit for a my project..
But cannot find one close by (Hampshire) can anyone courier one? Or anyone know a good place on the net to get a modest kit?
Old 06-06-2015, 03:37 PM
  #21  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default Starting to come together now

Latest photos to share on the van project.
The back is now ply lined
Old 14-06-2015, 10:54 AM
  #22  
kyle_st200
PassionFord Regular
 
kyle_st200's Avatar
 
Join Date: Dec 2008
Location: Grantham
Posts: 404
Received 5 Likes on 5 Posts
Default

Any more updates on this? Have you done anything about the windows yet?
Old 14-06-2015, 09:31 PM
  #23  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by kyle_st200
Any more updates on this? Have you done anything about the windows yet?
To be honest this week I have been flat out with work so I haven't had chance.
But the next thing to do is the windows. Hopefully this week I can get it into the workshop for the windows to be panelled and welded... Then it's official.. I have a van! Then I've got the body kit to fit... Then respray
Old 17-06-2015, 05:10 PM
  #24  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default Rear panels done!!







Old 18-06-2015, 11:16 AM
  #25  
kyle_st200
PassionFord Regular
 
kyle_st200's Avatar
 
Join Date: Dec 2008
Location: Grantham
Posts: 404
Received 5 Likes on 5 Posts
Default

That looks spot on!! How much did he charge to do that and do you have his contact details? It bugs me that the colour on my vinyl isn't 100% so want to do this and paint it. Did you just stick it on with some adhesive to the glass?
Old 19-06-2015, 03:04 PM
  #26  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by kyle_st200
That looks spot on!! How much did he charge to do that and do you have his contact details? It bugs me that the colour on my vinyl isn't 100% so want to do this and paint it. Did you just stick it on with some adhesive to the glass?
Initially we were going to take the window out and weld the panel in but found that if we did do that then we would loose the door seal so we just wrapped it in alloy and sealed it in like a windscreen. We also put a slight lip between the door and the glass so you would never know a window was there...(also it's a much stronger construction)
It's a mate of mine who builds security truck etc the company is Agenda down near Andover on the a303. Great guys. And was an easy hod for them.
Just need it painted once the kit is on
Old 19-06-2015, 07:20 PM
  #27  
kyle_st200
PassionFord Regular
 
kyle_st200's Avatar
 
Join Date: Dec 2008
Location: Grantham
Posts: 404
Received 5 Likes on 5 Posts
Default

What sort of price is it to get this done? It looks so good I want to do it to mine and paint it so it looks like a proper van
Old 21-06-2015, 04:44 PM
  #28  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by kyle_st200
What sort of price is it to get this done? It looks so good I want to do it to mine and paint it so it looks like a proper van
Not sure as me and a mate did the work (favour) but it took an afternoon, a sheet of 1mm alloy and some stickaflex.
Probably about Ł150 but it depends where you go and I'm not one to be pricing it up.
It's not that hard to do yourself really.
Just get the right stuff and take the time getting the template perfect
Old 21-06-2015, 05:53 PM
  #29  
mk1turboestate
Advanced PassionFord User
iTrader: (2)
 
mk1turboestate's Avatar
 
Join Date: Dec 2010
Location: manchester
Posts: 1,844
Received 73 Likes on 68 Posts
Default

Fair play to you mate for giving it a go, one thing that would be a one of a kind is if you blended the back quarter into one so it was more " van like" than covering the window
Old 23-06-2015, 12:19 PM
  #30  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

To blend or not to blend...
I did think about that but felt that leaving the edge in would make it look better. I thought that if I did blend it in as one then it would look too bubbly if you know what I mean.
But that's my opinion.
What does everyone think?
Old 23-06-2015, 12:25 PM
  #31  
RichieST
15K+ Super Poster!!
iTrader: (2)
 
RichieST's Avatar
 
Join Date: Aug 2004
Location: Wiltshire
Posts: 18,732
Received 449 Likes on 397 Posts
Default Focus St van conversion project

if I were repainting the whole car I'd blend them in but if you were leaving the paint I would leave them as is.
Old 23-06-2015, 02:47 PM
  #32  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

....complete colour change to either white or satin gun metal.
The panels are sealed to the body so it's a soft line instead of a gap
Old 23-06-2015, 08:06 PM
  #33  
mk1turboestate
Advanced PassionFord User
iTrader: (2)
 
mk1turboestate's Avatar
 
Join Date: Dec 2010
Location: manchester
Posts: 1,844
Received 73 Likes on 68 Posts
Default

My fear would be all the effort being put in to look like a focus with a painted back window, like the corsa above!, the focus above looks quality
Old 30-06-2015, 08:51 PM
  #34  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default




Custom front bumper coming along... Think I should of just bought an St one now rather than be original...a lot more work than I thought
Old 02-07-2015, 01:35 PM
  #35  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Moving on...
Bulk head finished with shelf
Old 02-07-2015, 02:49 PM
  #36  
RB26DETT
Regular Contributor
 
RB26DETT's Avatar
 
Join Date: Oct 2010
Location: Ireland.
Posts: 235
Received 12 Likes on 11 Posts
Default

Cool Project.
But why not just buy a factory Focus Van instead of converting?

Old 02-07-2015, 04:03 PM
  #37  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by RB26DETT
Cool Project.
But why not just buy a factory Focus Van instead of converting?

Yes this would of been easier however they never made them in the UK just Ireland
Old 02-07-2015, 04:12 PM
  #38  
Projectdave
15000
Thread Starter
 
Projectdave's Avatar
 
Join Date: May 2015
Location: Hampshire
Posts: 23
Likes: 0
Received 0 Likes on 0 Posts
Default

Originally Posted by Projectdave
Yes this would of been easier however they never made them in the UK just Ireland
....also I fancied the challenge!
Related Topics
Thread
Thread Starter
Forum
Replies
Last Post
gavt123
Pictures, video & Photoshop Forum
7
05-09-2015 10:03 AM
hopper350
Garage / Workshop & Tools Section.
2
04-09-2015 12:53 AM
CrOwSoN15
General Car Related Discussion.
14
03-09-2015 12:21 PM
STeve
General Car Related Discussion.
8
03-09-2015 10:49 AM
Bighandsuk
General Car Related Discussion.
0
02-09-2015 05:23 PM



Quick Reply: Focus St van conversion project



All times are GMT. The time now is 09:02 AM.