Horsebox build.....our story!

wow what a great thread and love seeing the progress. After recently selling our 7.5t DAF LF due to the purchase of a shire horse we are now looking for something bigger around the 14t mark, like you said the cost of buying one the conventional way is just staggering so the thought of having one made is the route we will have to take. Like you we would have external tack lockers which do not take up space in the horse area what with the big boy being 18h+ he needs all the space he can get! This thread is really great and giving us ideas and would you be able to tell me do they cater for larger lorries? Were based in Essex so would be nice and close to use them
 
Darbs said:
I would like to say I owned one, but I just worked for the manufacturer. Having said that, whilst horses may be expensive, try a large powerboat. The rough rule of thumb is 10% of the boats value per year to run and operate it, one of those costs about £600,000, so it will be about £60,000 a year to run it!
Click to expand...
Sounds like my daughter! Lol!
 
littlemiss1 said:
wow what a great thread and love seeing the progress. After recently selling our 7.5t DAF LF due to the purchase of a shire horse we are now looking for something bigger around the 14t mark, like you said the cost of buying one the conventional way is just staggering so the thought of having one made is the route we will have to take. Like you we would have external tack lockers which do not take up space in the horse area what with the big boy being 18h+ he needs all the space he can get! This thread is really great and giving us ideas and would you be able to tell me do they cater for larger lorries? Were based in Essex so would be nice and close to use them
Click to expand...

i think in retrospect it's worth speaking to them prior regarding the chassis....one of the issues we faced was the suitability and the rear axle location.... The reason Daf's are heavily used especially in the 12 tonne versions is they have a regular chassis that has a very long wheelbase and a short tail behind the rear axle which is ideal for horse transport especially with a big one like yours...

The primary idea is to get the main weight over the axle not behind the axle I.e. Not hanging out over the tail which causes weight issues...

Our Mercedes is great for what we want but has immediately caused issues with overall vehicle length... Because it has a relatively short chassis wheelbase. So we are at the maximum length permissible which has comprised us a little bit as ideally I'd have liked to have had another couple of feet.

The chaps at Courcheval have been incredibly knowledgeable in relation to this and thus am very grateful to use their professional experience...

The primary concern you need to consider is are you converting a ready built goods truck or are you considering having a purpose built coachbuilt body?

Needless to say I would give them a ring and pop along to see some in build..totally fascinating!
 
Farmer Chalk said:
I'm rapidly trying to reshuffle my design to try and incorporate a built in bin....!
Click to expand...

FC - We found it easier to use carrier bags/pedal bin liners, on a plastic attachment just inside one of the cupboards, like this one, but the one we had is a bit smaller, made for caravans: Takes up a lot less space, and you empty the bag daily into the larger bins outside, so less smelly :)

http://www.ebay.co.uk/itm/Carrier-B...-Door-Garage-Workshop-Motorhome-/151176835835
 
Farmer Chalk said:
Sounds like my daughter! Lol!
Click to expand...

Yes, understood! Worryingly I seem to be following your direction, with a 6 year old daughter who rides regularly (on other peoples ponies) and is gradually falling deeper into the equine cash pit of doom! (My cash pit of doom I hasten to add!).

I wouldn't have it any other way though, she loves being outside, mixing with lots of other people, spending all day every Saturday at the riding school stables. She has ridden 8 different ponies this year alone, some of which were a bit of a handful, and she loves every minute. She is currently poo-picking in the lounge using conkers as pretend poo and using a poo picker made out of an old dustpan!

I can see me creating a horsebox build forum thread in 15 years time!
 
Darbs said:
Yes, understood! Worryingly I seem to be following your direction, with a 6 year old daughter who rides regularly (on other peoples ponies) and is gradually falling deeper into the equine cash pit of doom! (My cash pit of doom I hasten to add!).

I wouldn't have it any other way though, she loves being outside, mixing with lots of other people, spending all day every Saturday at the riding school stables. She has ridden 8 different ponies this year alone, some of which were a bit of a handful, and she loves every minute. She is currently poo-picking in the lounge using conkers as pretend poo and using a poo picker made out of an old dustpan!

I can see me creating a horsebox build forum thread in 15 years time!
Click to expand...

You`re doomed :D :D :D lololol .... she`s already a horse woman :D
 
DJ said:
You`re doomed :D :D :D lololol .... she`s already a horse woman :D
Click to expand...

I think I am coming to terms with that! The truth is that whilst we do not come from a horse background, she absolutely loves it, and I would prefer spending £10,000 a year on her horse obsession than £500 on computer games. (Don't think from that comment that we have loads of excess cash washing around, its about what I would prefer to see her doing and being involved with). We are actually trying to balance it so that she retains her interest in swimming and cycling as well, I don't want her to burn out and loose interest in horses through over exposure to the horse world!

Right, I am off to trip over some more conkers!
 
It`s a good rouse to be fair ... I got into horses from being a tiny tot, and in my later years (teenager) I never had time for boys, which my father was always grateful for :D ... my pony always came first ;)
 
Ref colour, I would suggest that White would be a good choice as a base as it reflects the sun and the box will be cooler inside from my experience. Also it would be a good base for any sponsorship decals you might want to use in future.
 
Last edited:
Darbs said:
Yes, understood! Worryingly I seem to be following your direction, with a 6 year old daughter who rides regularly (on other peoples ponies) and is gradually falling deeper into the equine cash pit of doom! (My cash pit of doom I hasten to add!).

I wouldn't have it any other way though, she loves being outside, mixing with lots of other people, spending all day every Saturday at the riding school stables. She has ridden 8 different ponies this year alone, some of which were a bit of a handful, and she loves every minute. She is currently poo-picking in the lounge using conkers as pretend poo and using a poo picker made out of an old dustpan!

I can see me creating a horsebox build forum thread in 15 years time!
Click to expand...

Now that's what I call keen. Not just playing ponies but practising poo-picking.
Your daughter definitely has the bug:)
 
DJ said:
FC - We found it easier to use carrier bags/pedal bin liners, on a plastic attachment just inside one of the cupboards, like this one, but the one we had is a bit smaller, made for caravans: Takes up a lot less space, and you empty the bag daily into the larger bins outside, so less smelly :)

http://www.ebay.co.uk/itm/Carrier-B...-Door-Garage-Workshop-Motorhome-/151176835835
Click to expand...

Cool idea! We are struggling unfortunately because ordinarily where there would be a cupboard under the sink unit this is actually the rear of the tack locker from the other side of the truck...(if that makes sense...i.e.the sink is mounted on the top of the tack locker ) so we have very little cupboards at under work surface level....they will all be at eye level ....
But I could adapt the base of some drawer units.... This is the beauty of this thread as it is making us think of the practical demands needed in the truck! Thanks!
 
Darbs said:
Yes, understood! Worryingly I seem to be following your direction, with a 6 year old daughter who rides regularly (on other peoples ponies) and is gradually falling deeper into the equine cash pit of doom! (My cash pit of doom I hasten to add!).

I wouldn't have it any other way though, she loves being outside, mixing with lots of other people, spending all day every Saturday at the riding school stables. She has ridden 8 different ponies this year alone, some of which were a bit of a handful, and she loves every minute. She is currently poo-picking in the lounge using conkers as pretend poo and using a poo picker made out of an old dustpan!

I can see me creating a horsebox build forum thread in 15 years time!
Click to expand...


I read the above thread on my phone earlier but didn't have time to respond to it but I have been giggling to myself all day about it!
Trust me they will soon get bored of it!
If you feel the need to assist poo pick I've got a few acres that need doing...just think how healthy it will be out in the country air!

It has made me smile however as it doesn't seen long ago that my 16 yr old was laying a trail of sticks around the garden and spent the majority of the day doing horsey jumps between the rose bushes!

Unfortunately it has got a lot more expensive since then! For all my moaning I wouldn't change a thing.. It has showed her so many new skills, it has given her responsibility and learned a new respect for everything and as such she has turned into a well rounded individual rather than the chavettes who hang around the local Co-op....

And the other thing it has done is met some fabulously nice people around the circuit who are all like minded individuals out there doing the right thing!

Re the interesting and feisty horses...don't be frightened about riding them ( within reason)... This is where she will learn her horsemanship and learn to sit properly! We bought a beautiful but totally mental palomino when she was 10-11 but that horse taught her so so much and which is why we are reaping the rewards now!
:):):)
 
DJ said:
It`s a good rouse to be fair ... I got into horses from being a tiny tot, and in my later years (teenager) I never had time for boys, which my father was always grateful for :D ... my pony always came first ;)
Click to expand...


Ssscchhhush.....our secret....this is my real reason for doing it all..... Don't tell anyone!
 
Again thanks to all for your input....postman has been busy with deliveries of things like smoke detectors, external plug sockets etc etc....

Just arrived from Poland is the start of the interior materials.... 35 metres of Alcantara for the sleeper pod and the first four hides of brown saddle leather for the seating area.... Quite exciting and lovely colours..

image_zpsgtxfu0bg.jpeg
[/URL][/IMG]
 
Farmer Chalk said:
Ssscchhhush.....our secret....this is my real reason for doing it all..... Don't tell anyone!
Click to expand...

Heh heh heh .. thought it might be ....


Any more updates or has it all gone quiet over christmas? ... I like the fabric, though I did cringe a bit at the colour, I don`t know how long it will stay looking so new.
 
DJ said:
Heh heh heh .. thought it might be ....


Any more updates or has it all gone quiet over christmas? ... I like the fabric, though I did cringe a bit at the colour, I don`t know how long it will stay looking so new.
Click to expand...

Are you saying it's going to get covered in mud? ....
The beige is only going to be used to line the sleeper pod to make it a bit more airy and less claustrophobic....so hopefully the mud won't get that far! (Hmmmm)

We have had a slight delay prior to the Xmas just purely arranging the next phase...the living area obviously needs to be lined and so the wood panels have arrived and these have just been lacquered... A slight hitch is the outside lights and the 5 metre awning which is on order from Germany...these are required to be fitted prior to the internal build due to the wiring being run up inside the interior facing panels.....

But the shower is arriving tomorrow, the fridge and microwave and toilet have arrived, the toilet floor has been ordered so we should start to see some movement over the next few days...( hopefully )
 
Farmer Chalk said:
Are you saying it's going to get covered in mud? ....
The beige is only going to be used to line the sleeper pod to make it a bit more airy and less claustrophobic....so hopefully the mud won't get that far! (Hmmmm)
Click to expand...


Not mud 'per say' ... But horse hair, dirt, scurf, slobber (usually green from mouth fulls of grass), mud (dry/dusty) and mud (wet), and just general horse "muck n mess" tends to get everywhere, even if there is a "no boots" rule lol ... Hence why I cringe at the thought, I won`t have a vehicle (car/4x4) with a beige interior for pretty much the same reason. I am a bit (ok a lot) OCD though, but I would have chosen a mid/dark grey (like the colour on the right of the sheet that you rolls of fabric are sat on in the picture), or a mid Blue, and then "lightened" the POD with the sheets/pillow cases/duvet covers/curtains, all of which can be removed and washed/replaced with ease :)

Farmer Chalk said:
We have had a slight delay prior to the Xmas just purely arranging the next phase...the living area obviously needs to be lined and so the wood panels have arrived and these have just been lacquered... A slight hitch is the outside lights and the 5 metre awning which is on order from Germany...these are required to be fitted prior to the internal build due to the wiring being run up inside the interior facing panels.....

But the shower is arriving tomorrow, the fridge and microwave and toilet have arrived, the toilet floor has been ordered so we should start to see some movement over the next few days...( hopefully )
Click to expand...

Sounds like it`ll motoring along again in no time at all (no pun intended lol) ... Looking forward to hearing the updates.
 
Last edited:
:(:( You've obviously seen our old Range Rover! I swear that the insides move by themselves.....I could grow a healthy crop of potatoes on our back seats!

a short funny story..... I used said Range Rover to collect four wheels and tyres that I was selling to a third party. We had arranged to meet at a convenient place 30 minutes from home...so I loaded the wheels and they were in the car for less than 30 minutes...
I arrived at the location first and thus unloaded said wheels prior to the arrival of the other chap. He arrived a few minutes later and I helped him put the wheels on his roof rack.... As he was lifting them he uttered the immortal words....' Mate your tyres smell of horse piss! How I laughed not!!
unfortunately you horsey people will know exactly what I mean! :)
 
Farmer Chalk said:
Cool idea! We are struggling unfortunately because ordinarily where there would be a cupboard under the sink unit this is actually the rear of the tack locker from the other side of the truck...(if that makes sense...i.e.the sink is mounted on the top of the tack locker ) so we have very little cupboards at under work surface level....they will all be at eye level ....
But I could adapt the base of some drawer units.... This is the beauty of this thread as it is making us think of the practical demands needed in the truck! Thanks!
Click to expand...

In our old caravan we had one of these on the end of the unit just by the door. I've seen them on the actual van doors, so they swing outside and out of the way when using the door..
 
Now prepared for next phase which should start moving along quite quickly now I'm hoping...

Just started the interior, and needed to preempt a few things...the exterior lights have started to go on as the wiring needs to drop down inside the interior panels first...slightly held up still waiting for the electric awning ...we've been told it's been made and is now in transport from Germany...this ideally needs to go on first as we don't know exactly where it's going to bolt through the body or where the electric wires are going to intrude through the body....

So started with the bathroom.... We were trying to ensure the floor remained waterproof as we were having a shower enclosure fitted...looked at various products...Lino, tiles, laminate etc but it needed to be 100% waterproof but also not too slippery when wet and muddy (apparently) ....

So as we are not at all worried by weight I bought 3 large slate tiles which were a perfect fit and only had to cut down one to get them to fit neatly...
Cut out the areas where the shower waste will pass through the body and where the toilet overflow passes out. Decided on a bit of a wet room so I can easily wash it out without puddles of water so fitted a central drain with hose tails which passes through the tiles and floor and vents under the truck....

image_zpsfgpawucw.jpeg
[/URL][/IMG]

Monday the white waterproof side panels should go in then we can fit the shower and toilet properly. Then the up stands will be fitted around the bottom edges to seal the floors off...
image_zpsrhpneusr.jpeg
[/URL][/IMG]


Also sorted our bin problem....thanks for the great advice given here..sourced a big bin which will slide out on runners which will fit inside the side under cupboard next to the sink... Just placed it here for sizing reasons ....

image_zps1qg5qrf4.jpeg
[/URL][/IMG]

So hopefully we should now start cooking with gas for the build now!

Thanks again for all the advice! Incredibly helpful!
 
Not sure if this has been mentioned before but in our old decrepit lorry the previous owner had the cupboard doors fitted with child lock catches, not to prevent a child from opening them but to prevent the doors from coming open on sharp bends
 
Well the interior has now started with a vengeance...the walls are starting to be lined with the wood panels.... Basically these are laid up against the exterior walls and when they cut the window holes out they cut through both panels simultaneously for neatness....

image_zpsjc6iigfy.jpeg
[/URL][/IMG]

This panel shown will be the right side of the truck, and will have a number of cupboards on this side eventually...


The next photo shows the doorway and the beginning of the installation of all the light switches, the generator control panel and all the respective wiring which has to go in behind all the panels,

image_zpsknidpel2.jpeg
[/URL][/IMG]


image_zpsdvgm5nig.jpeg
[/URL][/IMG]

So lots of wiring and plumbing going behind the panels ......

Really will start taking shape at a fast speed now! :)
 
Farmer Chalk said:
:(:( You've obviously seen our old Range Rover! I swear that the insides move by themselves.....I could grow a healthy crop of potatoes on our back seats!

a short funny story..... I used said Range Rover to collect four wheels and tyres that I was selling to a third party. We had arranged to meet at a convenient place 30 minutes from home...so I loaded the wheels and they were in the car for less than 30 minutes...
I arrived at the location first and thus unloaded said wheels prior to the arrival of the other chap. He arrived a few minutes later and I helped him put the wheels on his roof rack.... As he was lifting them he uttered the immortal words....' Mate your tyres smell of horse piss! How I laughed not!!
unfortunately you horsey people will know exactly what I mean! :)
Click to expand...


ROFL !!! I know EXACTLY what you mean !!!! Ha ha ha ha ha ha ha !!!

Great new pictures too, it`s coming together so well :) and that bin is a great idea !!
 
I cannot believe I have only just discovered your thread!! It is so interesting, can't wait to see the finished product :) We too are just at the point of looking for a lorry this sort of size and can't figure out where to look first - everything is just so expensive...phoned one manufacturer and was told that 100k was no where near a proper budget for a 14tonne lorry (I haven't said it has to be new) and I need to go away and save up a proper budget :( You have made the process of doing it yourself so to speak so much less daunting so thank you FC.
FWIW going back to your post about keeping stuff safe in the cupboards, we currently have a 7.5t Oakley and the cupboards in that have push buttons to open them but inside there is a metal bar that is a few inches up and this just holds all the plates/mugs etc in place rather than falling on your head every time you open the door.
 
Welcome along for the ride!

And thanks for your ideas.....;)

Update for today... I think I have started my 'man-opause' with this lorry... Had a long meet with the great guys at Courcheval to discuss electric needs and how we hope to run the lorry at shows... Hence begins the miles and miles of wires running fore and aft...

Yesterday I went to the boat show at Excel London ( must be mental... Think I'm having another hot flush already ) purely to meet an exhibitor or two...

The purpose, .... I wanted to source the type of fittings found in the top end boxes like Oakley and Lehel, STX etc...
Company there called Timage based in Essex who supply most of the door catches, lights, locks etc....

So have sourced our drawer and cupboard locks now...

Also recently went to a local Stone masons and have given him the sizes and potential template for a lump of granite hopefully to be turned into our new kitchen work surface......

So trying to do things on the cheap but fit out the lorry with a top end type fitment... It's never going to be a full on £150 k lorry but by goodness I'm going to try and make it look and more importantly feel like one!

Keep the ideas flowing!

Thanks to all for your input! :):):)
 
Spottyappy said:
Won't granite add huge weight to the payload, if you use that in the kitchen?
How much payload are you envisaging to end up with?
Click to expand...

I was thinking the same, I know you`ve gone with a larger lorry to not have to worry too much about weight, however a nice Beech butchers block worktop will give a similar upmarket feel with out the weight :)
 
Another tip - OH fitted some child locks on our cupboard doors for the same reason. He fitted them so they would be at their maximun strength if stuff was thrown against them... except... often in a box you are doing 2 things at once, and are opening cupboards one handed, and the catches were not right level with the handles, so needed 2 hands to flip the catch.

A small thing, but enough to drive you mad if you are rushing. If they were level with the handles it can all be done in one smooth action, even with one hand!
 
You must log in or register to reply here.
Top