Transforming A 1993 Aerostar Into A Cozy Camper

The Ford Aerostar is a minivan that was produced from 1986 to 1997. It was unusual for its time, offering refined handling, performance, and quality. Its all-wheel-drive system provides better traction on wet roads, and its powerful engine and soft yet firm ride make it a comfortable and easy-to-handle vehicle. The Aerostar's seating arrangements, however, are less convenient than those of its competitors, the Mercury Villager and Nissan Quest. Converting a 1993 Ford Aerostar into a camper van requires careful planning, especially when it comes to powering electronic devices and appliances.

Powering electronic devices

Battery Bank:

Start by installing a battery bank, which will serve as the power source for your electrical system. The battery bank typically consists of one or more batteries that store energy and release it to the connected devices when needed. You can use deep-cycle batteries, lead-acid batteries, or lithium batteries, depending on your budget and specific needs. Calculate the power requirements of your electronic devices to determine the size and number of batteries needed.

Charge Sources:

Next, you'll need to set up charge sources to keep your battery bank energised. Here are some options:

• Solar Panels: Installing solar panels on the roof of your Aerostar is an excellent way to harness the power of the sun to charge your batteries. The number of solar panels you install will depend on your power requirements and available roof space.
• Alternator: The alternator in your vehicle can also be used to charge the battery bank. Devices like DC-DC chargers or isolators can be installed to transfer power from the alternator to the batteries while the engine is running.
• Shore Power: When you're near civilisation, you can plug into an electrical outlet to charge your batteries. You'll need an AC-to-DC charger to convert the power from the outlet (typically 110-120V AC) to the 12V DC power your batteries need.

Loads:

Finally, you need to consider the loads, which are the electronic devices and appliances that will draw power from your battery bank. These can include lights, fans, a fridge, and charging ports for your devices. If you want to power devices that use standard household outlets (110-120V AC), you'll need an inverter to convert the 12V DC power from your batteries to 110-120V AC. Be mindful of the power draw of each device, as high-power appliances like air conditioners or space heaters may quickly drain your battery bank.

Important Considerations:

• Battery Maintenance: Ensure you understand how to properly maintain your chosen battery type to maximise its lifespan and performance.
• Wiring and Fuses: Consult a professional or a detailed wiring guide to ensure your electrical system is set up safely and correctly. Use appropriate wiring gauges and fuses to prevent overloading and potential hazards.
• Charging Routine: Develop a routine to keep your battery bank charged. This may include driving your vehicle regularly, parking in the sun to maximise solar charging, or plugging into shore power when available.
• System Monitoring: Install a battery monitor to keep track of your battery's state of charge. This will help you avoid completely draining your batteries, which can reduce their lifespan.

Storage and batteries

Storage Ideas

• Maximise space and get creative with how you store your belongings. For example, use multi-use tools and nested and expandable cookware.
• Elastic nets and storage containers can help keep food in place in your food cupboards.
• Sealable containers are key to keeping food fresh and preventing rodents.
• Magnetic wall racks are a space-saving way to store eating or cooking utensils.
• Vertical storage solutions can help utilise open space inside your van.
• Under-seat storage and storage benches are great for keeping items off the floor and creating a sense of spaciousness.
• Packing cubes can help save space and keep your folded clothes organised.
• Shoe pockets can be used on seats, doors, or anywhere you want to store shoes and other small items.
• Vacuum bags can maximise storage space, but beware that they can pop while driving over mountain passes at high altitudes.
• Hidden storage solutions, such as tip-out trays and storage pockets on doors, can create a visually appealing interior while also providing functional storage.

Battery Setup

• Your campervan electrical system will consist of a battery bank, loads, and charge sources. The charge sources add energy to the battery bank, which stores the energy and releases it to the loads when needed.
• There are typically two battery banks: the factory starter battery to start the engine and power the vehicle’s systems, and the auxiliary "house" battery to power all the campervan systems (fridge, lights, fan, etc.).
• When selecting a battery type, consider the pros and cons of different chemistries such as flooded lead-acid, sealed lead-acid (including AGM and gel), and lithium-ion. Factors to consider include maintenance requirements, temperature range, charge/discharge profile, weight, dimensions, life cycle, and cost.
• To maximise the life cycle of your batteries, follow the recommended charge and discharge profiles, avoid deep discharges, store them at moderate temperatures, and periodically recharge them if they will be unused for extended periods.
• When combining multiple batteries, use identical cables to ensure equal current and voltage distribution, and avoid mixing batteries of different brands, models, or ages.
• To determine the size of your battery bank, calculate your total electrical load by listing all your appliances, their voltages, amps, and estimated usage time. Then, decide how many days of off-grid usage you want, and multiply your total load by that number. Finally, double that value if using lead-acid batteries to account for the recommended 50% depth of discharge.
• You can charge your leisure batteries through solar panels, a split-charging system connected to your vehicle's alternator, or by plugging into shore power (a house outlet or campground hookup). The time it takes to charge your batteries will depend on the charging method, battery type, ambient temperature, and the C-rating of your batteries.
• To protect your electrical system, install fuses or circuit breakers near the battery terminals and use a battery monitor to track the health and charge level of your batteries.

Appliances and power

The 1993 Ford Aerostar is a great candidate for a DIY camper conversion, but it's important to carefully consider your power needs and choose the right appliances to avoid overloading your electrical system. Here are some tips and suggestions for appliances and power in your camper:

Power Sources

When it comes to powering your camper, there are a few options to consider:

• Solar Power: Solar panels can be a great way to generate clean and quiet energy for your camper. They are typically lightweight, low-maintenance, and can be installed on the roof or portable ones can be set up at your campsite. Keep in mind that solar power can be unpredictable depending on weather conditions and the amount of sunlight available.
• Alternator: The vehicle's alternator can be used to charge a secondary battery, which can then power your appliances. However, alternators are primarily designed to charge the starting battery and may not provide a full charge cycle for deep-cycle batteries.
• RV Hookups: If you plan to stay at campgrounds or RV parks, you can take advantage of electrical hookups. This option provides a consistent and reliable power source but may require additional equipment such as adapters and power cords.
• Generator: A generator can be a practical solution, especially if you need to power high-demand appliances like air conditioners or microwaves. They can be easily moved and don't rely on sunlight or a running engine like solar panels and alternators. However, generators can be noisy, require fuel, and produce carbon emissions.

Battery Options

When choosing a battery for your camper, consider the following:

• Deep-Cycle Batteries: These batteries are designed for frequent and deep discharges, making them suitable for powering appliances in a camper. They can be charged using solar panels, the alternator, or other power sources.
• Lithium Batteries: Lithium batteries are more expensive upfront but offer several advantages. They have a longer lifespan, higher usable capacity, and are generally lighter in weight compared to other types. They also have a low self-discharge rate, so you don't need to recharge them as frequently.
• AGM (Absorbent Glass Mat) Batteries: AGM batteries are a type of lead-acid battery that is low-maintenance and performs well across different temperature ranges. However, they are generally heavier and have a shorter lifespan compared to lithium batteries.

Power Management

To ensure you have enough power and avoid overloading your electrical system:

• Calculate Your Power Needs: Determine the wattage and amperage requirements of the appliances you plan to use. This will help you size your battery bank and solar panels accordingly.
• Consider a Power Inverter: A power inverter converts the 12V DC power from your battery to 120V AC power, allowing you to plug in standard household appliances. However, keep in mind that inverters can draw a significant amount of current, so size your battery bank accordingly.
• Use Energy-Efficient Appliances: Look for appliances with energy-saving features or those that run on 12V DC power directly, such as LED lights, DC fans, and energy-efficient refrigerators. This will help reduce your power consumption and prolong your battery life.
• Prioritize Your Appliances: If you have limited power, prioritize essential appliances like lighting, a small refrigerator, and device charging. You can also consider using propane or gas appliances for cooking and heating water to reduce your electrical load.

Appliance Suggestions

• Lighting: LED lights are energy-efficient and can be powered directly from your 12V battery. Look for dimmable options to conserve power and create different moods.
• Refrigeration: A compact refrigerator is a valuable addition to any camper. Consider a 12V DC refrigerator or a three-way refrigerator that can run on propane, 120V AC, or 12V DC power.
• Cooking: Instead of a built-in stove, consider a portable propane or butane camp stove. They are compact, inexpensive, and don't require any electrical power. For cooking indoors, an induction cooktop or an electric skillet can be good options.
• Water Heating: If you need hot water for dishes or showers, consider a small tankless water heater that runs on propane. Alternatively, you can invest in a larger water heating system if you have the space and power capacity.
• Device Charging: USB charging ports and power outlets can be installed to keep your phones, tablets, and other devices charged. Look for USB outlets with multiple ports to charge multiple devices simultaneously.
• Microwaves and Toasters: These appliances can be convenient for quick meals and snacks. However, they consume a significant amount of power, so consider using them sparingly or only when hooked up to shore power.
• Air Conditioning and Heating: Air conditioning and heating can be power-intensive. Consider a portable air conditioner or a diesel heater that runs on propane, as they don't require as much electrical power.

Sleeping arrangements

The 1993 Ford Aerostar has two rows of bench seats that can be folded into a bed. This is a nice feature, but it takes a little work to flip the levers and push the heavy seat cushions. Removing the seats is a two-person job as they are heavy and cumbersome.

If you are looking to convert your Aerostar into a camper, you could consider chucking the rear seating and building a platform bed (or narrow bunks) with storage underneath. You could also use magnets and window screening cut to size to give yourself ventilation while keeping the bugs out.

If you are camping in mountainous areas with steep grades, you may want to consider the suspension and engine options of your Aerostar. The Aerostar has been described as "a little weak in the suspension and a little weak in the engine options". The 4.0L V6 engine is also described as "anemic", generating 155 hp.

If you are planning to power any electronic devices within the vehicle, you will need to consider your power options. You could use deep-cycle batteries, either purchased or built from plywood and nails, and connect them to power inverters. However, this is a complicated process and you will need to know what you want to power and for how long to determine the number and size of the batteries.

Overall, while it may be possible to convert a 1993 Ford Aerostar into a camper, there are some considerations and challenges to keep in mind, especially regarding space, power, and engine performance.

Removing seats

Removing the seats from your 1993 Ford Aerostar is a great first step in converting it into a camper. The Aerostar's seats are bolted to the floor, so you'll need to locate and remove the bolts to free the seats. Here's a step-by-step guide:

Gather Your Tools:

You will need a socket wrench and sockets that fit the bolts in your Aerostar. You may also need a screwdriver and a pry bar, depending on the seat configuration.

Remove the Front Seats:

• Locate the bolts securing the front seats to the floor. These bolts are typically found at the base of the seat, where it meets the floor. There may be two or four bolts per seat.
• Use your socket wrench to loosen and remove these bolts. Set the bolts aside in a safe place, as you'll need them later if you decide to reinstall the seats.
• With the bolts removed, carefully lift the front seats out of the vehicle. You may need a helper for this step, as the seats can be heavy.

Remove the Middle Seats (if equipped):

• The middle seats in the Aerostar are typically bucket seats or a bench seat.
• For bucket seats, locate the bolts securing the seats to the floor and remove them. The middle seats may also have a lift and tilt mechanism that needs to be disconnected.
• For a bench seat, you may need to fold down the seat back and locate the bolts underneath. Remove these bolts and lift out the seat.

Remove the Rear Seat:

• The rear seat in the Aerostar is typically a bench seat that can be folded down or removed.
• Fold down the seat back and locate the bolts securing the seat to the floor. There may be two or four bolts, depending on your specific model.
• Remove these bolts and carefully lift out the rear seat.

Store the Seats:

Once all the seats are removed, you'll need to find a place to store them. Keep the bolts with the seats, as you'll need them if you decide to reinstall the seats later. Storing the seats in a dry, covered location will help keep them in good condition.

Converting your 1993 Ford Aerostar into a camper offers a fun and unique way to enjoy the outdoors. Removing the seats is a crucial first step in creating a spacious and functional living area. Remember to take your time, work carefully, and always follow safety guidelines when working on your vehicle.

Frequently asked questions