Camper Conversion: Diy Van Life Dreams

Converting a van into a camper is a great way to save money on accommodation and travel costs. It can be an affordable alternative to buying an RV or a tiny home, and it gives you the freedom to explore and experience new places.

There are a variety of vans that can be converted, each with its own pros and cons. Here are some of the best options:

- Ford Transit: This van offers different length and height configurations and is affordable for repairs and maintenance. It has three body lengths, two wheelbases, three roof heights, and three engine options. The newer models also offer intelligent all-wheel drive.

- Mercedes Sprinter: The Sprinter is a popular choice for van conversions due to its spacious interior and four-wheel-drive options. It comes in standard or high-roof models, with two powertrain options and multiple wheelbase and body length configurations. However, it is more expensive than other options, and maintenance costs can be high.

- Ram Promaster: The Promaster offers good value and is available in multiple configurations, including three wheelbases and two exterior height options. The interior front dash is more modern than the Ford Transit, but some find the aesthetics lacking, and it has low ground clearance.

- Chevy Express: The Chevy Express has been around for decades and is a good choice for DIY conversions due to its simple interiors and long-lasting chassis. It comes in 1500, 2500, and 3500 versions, but roof height options are limited, and it may be challenging to find used models.

- Nissan NV: The Nissan NV stands out for its truck-like nose and is available in standard or high-roof models. It offers reasonable value, but some find the basic trim models too basic, and it doesn't get great gas mileage.

Choosing a van for conversion

There are many factors to consider when choosing a van for conversion. Here are some key points to keep in mind:

• Budget: The cost of the van itself, as well as the cost of conversion, should be considered. Used vans can be a more affordable option, but it is important to carefully inspect them for any issues.
• Size: Think about how much space you will need for living and storage. Consider the number of people and pets travelling, and whether you need to stand up inside the van.
• Fuel Type: Decide between gas and diesel engines, taking into account fuel efficiency, performance, and maintenance.
• Features: Determine what features are important to you, such as standing height, windows, and built-in amenities.
• Reliability: Research the reputation of different van models for reliability and common issues.
• Conversion Options: Decide whether you want a DIY conversion or a pre-built conversion kit.
• Test Drive: If possible, test drive different vans to get a feel for their handling and comfort.
• Personal Preference: Ultimately, choose a van that suits your personal style and meets your specific needs.

Planning the layout

But laying out your van effectively also takes forethought and some careful planning. You need to figure out how best to cram everything you need into a small space, all while keeping it comfortable and livable.

How many people will be living in your camper van? One, two, three or more? Do you live with pets? More people means more bed space or additional convertible sleeping areas. And don’t forget that you’ll need enough open hangout space for everyone as well.

Do you want a permanent bed or a convertible one? A bed that converts during the day makes the interior much more usable, but can be a drag to set up every night and cuts down on space for storage. A permanent bed setup is easier to deal with and allows for more storage, but takes up more room. This can be an issue in such a tiny space, but is less of a problem in larger vans like the Sprinter or Transit.

How tall are you? If you’re over 6’ tall, layouts where the bed goes across the van will prevent you from comfortably stretching out. But if you’re short, crosswise beds won’t be a problem.

How much storage space do you need? Do you have a lot of clothes, instruments, equipment, books, or other things you just can’t part with? We highly advise downsizing as much as possible, but you’ll need a place to store everything you’re bringing.

Do you want to have windows and natural lighting? Windows and natural light help your van feel bright and open. But windows are less stealthy, and they also prevent you from putting in full-height furniture and storage areas. Some vans already have windows and some don’t, but you can always cover up existing ones or install your own.

How much power do you need? The larger power system you have in your rig, the more space it will take up.

Do you need somewhere to sit and work? If you do computer-based work on the road, consider including a comfortable seating area with a table in your layout. Tables are also great for meals and congregating.

Do you plan to cook inside your camper van? If you see yourself doing a lot of cooking, it’s a good idea to include a full campervan kitchen with a water tank, counter, sink, fridge and stove. You’ll also want to include enough space for dry food storage.

Do you have large items like dirt bikes, surfboards, or mountain bikes that you need to haul? Some camper van layouts include storage space for such items inside the van, or you can look at options for hitching them on.

When planning your layout, make sure to even out your van’s weight distribution. This means you’ll want to avoid putting the heavy items (batteries, water tanks, etc.) all on one side. In our camper van, we installed the water tank on the driver’s side and the batteries on the passenger’s side to help keep weight evenly distributed.

You’ll also want to think about distributing weight in the right places for traction. For example, if you have a rear wheel drive van, placing the heaviest items near the rear wheels will help increase traction.

Making Sure Everything Has Multiple Functions

When you live in a small space like a camper van, it’s a good idea to include multi-function items wherever possible. For example, having a kitchenette that’s also a structural support for a pull-out queen-sized bed frame. Or having a passenger seat that swivels, which makes it functional for hang out seating and really opens up the tiny space in a van.

Designing your van build layout with an eye towards multiple uses for everything will help you include all the functionality you need while still creating a comfortable and inviting space.

Insulation

Types of Insulation

There are two main types of campervan insulation:

• PIR (polyisocyanurate)
• EPS (expanded polystyrene)
• XPS (extruded polystyrene)

Other types of insulation include:

• Polyurethane spray foam
• Reflective bubble foil
• Fibreglass wool
• Rockwool
• Sheep's wool
• Aluminium bubble foil
• Closed-cell polyethylene foam sheets

Best Types of Insulation

Solid insulation boards, such as PIR boards, are the best choice for campervan insulation because they offer the highest thermal resistance for effective heat retention. They are lightweight, fairly cheap, and have a high R-value. Kingspan Kooltherm PIR boards have the highest thermal resistance, but Celotex and Recticel boards are more cost-effective.

For loose-fill wool insulation, polyester wool is a great option because it's light, cheap, and usually made from recycled bottles.

Installation

When insulating your van, it's important to build from the ground up. Start with the floor, then move on to the walls and ceiling. Make sure to insulate all areas of the van, including the doors and wheel arches. Use a combination of solid boards and loose-fill wool to insulate the van effectively.

For solid insulation boards, cut the boards to size and secure them in place with adhesive or tape. For loose-fill wool, tear the wool into lengths and stuff it into the cavities, minimising any gaps where heat can escape. Use spray adhesive to hold the wool in place.

It's also important to install a vapour barrier to reduce the risk of moisture getting into the cavity. This can be done with aluminium bubble foil or a reflective insulation material such as Low-E.

Electrical and solar

The electrical system is one of the most important parts of a camper conversion. It can also be one of the most daunting. It is essential to understand the basics of the electrical system before diving into the nitty-gritty of wire gauge, amps, volts, and watts. The basis of every camper van electrical system is the same: batteries, how you charge them, and how you discharge them.

There are three ways to charge camper van batteries:

• Using solar power and a solar charge controller
• Using a DC-DC charger between the chassis battery and the house battery
• Using shore power and an inverter/charger

There are two ways to deplete camper van batteries:

• Using DC power (direct current)
• Using AC power (alternating current)

Components of Your Van's Electrical System

#### Batteries

There are two main types of batteries in camper van systems: Lithium Iron and AGM (Absorbed Glass Mat). The decision is often brought down to a combination of budget, weight, and battery life. AGM batteries are cheaper, heavier, and can only be discharged to half capacity before sustaining damage. Lithium Iron batteries are more expensive, lighter, and can be discharged nearly fully.

#### Inverters and Inverter Chargers

Inverters convert the power in your batteries to usable power. Inverter chargers add another capability to your electrical system with the ability to charge your house batteries with shore power.

#### MPPT Solar Charge Controller

A solar charge controller is needed if you want to use solar panels. It converts the voltage of the solar energy you harvest and delivers it to your batteries at the optimal voltage that is safe for them to charge at.

#### Bus Bars or Lynx Distributors

Bus bars and Lynx Distributors are used to extend the positive and negative terminals in a clean manner. Lynx Distributors are a modular bus bar that has space for equipment circuits and fuses.

#### AC Distribution Panel

An AC distribution panel is similar to the function of your DC fuse panel. It provides individual circuit breakers for each AC circuit.

#### Master On/Off Switch

A master on/off switch is essential to enable safe servicing of your camper van electrical system. It allows power to be turned off to all devices individually.

Additional Camper Van Electrical System Considerations

#### System Voltage

Most van electrical systems are 12V. However, there is also a place for 24V systems in some situations. The larger the battery capacity system, the higher the battery voltage is appropriate.

#### Selecting the Correct Wire Gauge

There are only two pieces of information you need to select proper wire gauge: the current of the load and the distance that load has to travel from the power source to the appliance.

#### Protecting Your Camper Van Electrical System

Fuses, wire sheath, and wire conduit are all ways to protect your electrical system. Fuses are an essential part of any campervan electrical system and probably the most known way to protect an electrical system. Wire sheath is an expandable braided sleeve that adds a layer of resistance to rubbing and cutting. Wire conduit is a plastic-y covering that you slide over the wires as a final layer of protection.

Ventilation and cooling

Ventilation is an important aspect of your campervan conversion, as it helps to regulate airflow, bringing in fresh air and getting rid of the old, damp, and funky air. Without adequate ventilation, excess heat and water vapour can cause condensation, which can lead to further humidity, odour, and the growth of mould and fungus.

There are two types of ventilation: passive and active. Passive ventilation uses natural air currents and the buoyancy of hot air to circulate air in and out of your campervan. Active ventilation, on the other hand, uses power-driven fans to constantly work without relying on natural air pressure.

Passive Ventilation

Passive ventilation is generally a much cheaper option and is very reliable, with little to no maintenance required. However, it is not as effective in higher temperatures and can cause a draught if it's cold or windy outside.

• Opening the cab windows is the easiest and cheapest way to ventilate your van, but it is also the least effective, especially in larger vans.
• Window grills or deflectors can be installed to keep your camper secure while the windows are open.
• Additional opening windows in the van's panels allow for more air circulation and are more secure than simply opening the cab windows.
• Floor and wall vents provide constant air circulation without the need for open windows. They are more secure but don't let in any natural light.
• Circular vents can be installed like louvre vents or fitted inside your camper under a bench to improve air circulation.
• A 12V vent is a small, powered wall vent that can be used independently or as part of a circulatory system.

Active Ventilation

Active ventilation can work around the clock as long as there is a power source and will quickly cool and ventilate your campervan. However, it requires maintenance of wires and moving parts and only ventilates when the fan is on.

• Roof-mounted powered fans, such as the popular MaxxFan and Fantastic Fan, provide forced ventilation and are very effective at getting the inside temperature down close to the outside temperature.
• Evaporative cooling uses the evaporation of water to cool an air stream and can be quite effective, especially in low humidity conditions. Commercial units like the TurboKool can cool about 750 cubic feet per minute of air by 20 to 30 degrees Fahrenheit.
• "True" (compressor-based) air conditioners provide good cooling even in hot and humid conditions but require a lot of electrical power to run and are therefore not ideal if you want to be independent of shore power or generators.

When choosing a ventilation system for your campervan, consider your budget, the size of your van, and the climate you'll be travelling in. If you're on a tight budget, passive ventilation solutions like opening windows or installing additional vents may be sufficient. If you're travelling in hot climates, you'll need more ventilation to keep your camper cool and fresh. And if you want to be able to operate your ventilation system independently of shore power or generators, you'll need to invest in a more efficient system, such as a high-efficiency air conditioner or an evaporative cooler.

Frequently asked questions