In reply to gavmac:
> Thanks, sounds really interesting. Would love to see more info on that. >
The Sharan/Galaxy/Alhambra was a collaboration between VW (engines) and Ford (body) introduced in '95 with minor modifications until 2006 when Ford went alone with a completely new design, the Sharan/Alhambra carried on until 09 (possibly 10?) before a major redesign.
There are only a few cosmetic differences between the different makes (they were all made in the same factory anyway). New, the VW's cost more and the Alhambra was cheapest but at the age I was looking at there was no noticeable difference.
The deisels all shared the 1.9Tdi engine until the very last year or so (2009?) when some got VW's 2.0Tdi. I believe this is supposed to be a bit more refined (but the 1.9 seems fine to me) but less durable and for that reason alone I'd get a 1.9.
The rear seats are all removable easily to switch between 7, 5 and 2 seats. If I want more storage space I can take out all the rear seats, in the photos I've left the middle row in with the sleeping platform over the top of them.
After the major redesign (Ford '06 and VW '09) the seats fold into the floor, possibly more convenient but I don't know how it affects the internal space. As far as I know none of the new shapes have a spare wheel which rules them out for me. The new shapes also have sliding rear doors which the old shapes didn't if that makes a difference.
If buying one, watch out for wheel arch rust (Ford bodies!) and especially bodged up resprays and check the aircon works properly. It should be icy and don't be fobbed off by being told it just needs a regas. Its a common fault, if it doesn't work assume it needs a new compressor (about £400 fitted) so factor that in.
Not all have the sliding rear parcel shelf or rotating front seats, I had to get all of them from a breakers (on ebay) and fit them myself.
I bought the lowest spec model because they have manual rear windows - easier to open/close at night when sleeping in it.
Regarding the plywood boxes, I used 12mm birch ply which is a much better quality ply, stronger, screws better (no voids), doesn't really warp, and doesn't splinter. Any thicker than 12mm would be too heavy.
After I'd worked out the sizes I had all the pieces cut at a timber yard for greater accuracy/neatness than I could do with a circular saw. It would be well worth finding a place that can do this or find a joiner to do it? I then just had to glue and screw it together.
It cost me about £150 for the wood, cutting and hinges etc. so not much really.
One point to note is that the floor pan slopes down towards the front of the car so the sides of the boxes have to slope to make a level platform.
If you decide to get one and want to make the plywood boxes I can email you the plans with dimensions which I drew up which would make it rather easier, just email me through UKC.
Hope all that helps, good luck.