Transforming Astro Vans Into Cozy Camper Trailers

how to build a camper trailer from a astro van

Converting a van into a camper trailer is a great way to create a mobile living space. In this guide, we will be discussing how to build a camper trailer from an Astro van, a popular choice for van life enthusiasts due to its size, stealth, and decent gas mileage. The process involves gutting and insulating the van, installing a subfloor and flooring, adding electrical wiring and storage, and creating a comfortable living space within the vehicle. With careful planning and the right tools, you can transform an Astro van into a cosy and functional camper trailer, ready for your next adventure.

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Flooring

The flooring phase consists of two main parts: installing the subfloor and installing the flooring material. The subfloor provides a flat, smooth surface for the flooring to sit on. Most people use plywood for the subfloor, which will need to be fastened to the van by drilling holes through the subfloor and into the van's metal floor. Deck screws are good for this.

When choosing a flooring material for your van build, you will likely take multiple things into consideration. These include durability, looks, waterproofness, ease of cleaning, ease of repairing/replacing, price, and availability. Common types of flooring in van builds include sheet vinyl, interlocking vinyl planks, stick-on tiles, rubber flooring, linoleum, and laminate planks.

For this build, I’ve chosen vinyl planks for my flooring material. They are waterproof, easy to clean, durable, replaceable, and they look great. The floor is a small space, so the cost of choosing a high-grade flooring product makes sense for the look and utility it provides.

I’ve installed vinyl flooring planks a few times before in houses. They are easy to install, but it’s a slow and tedious process. Custom-cutting the planks to fit around things is very time-consuming, and this part of the installation takes the most time. It’s fairly easy to cut, but you might find that it takes a variety of tools for different cuts. I used a miter saw and a jig saw frequently, as well as a bench grinder to grind away parts of the plank leaving a smooth, rounded shape.

My van is wider than a sheet of plywood, so my subfloor will span two 4x8 sheets of plywood side by side. I’ll tape down the template to the wood so it doesn’t move, then trace a line on the plywood. With the template traced out, it’s time to cut the plywood into my new subfloor. I place the plywood over a couple of sawhorses and use a jigsaw to make these cuts.

Now, I’ll add pieces of furring strips around the edge of the van to match the height of the ribs running along the floor. This will avoid flex in the floor. After the construction adhesive has cured and the furring strips are in place, I drop the insulation back in, then lay the subfloor over the insulation. One key thing to remember about installing a subfloor is that there needs to be a gap of about 1/4" around the edges to account for expansion.

Next, I add some pieces of painter's tape at the back of the van, marking the ribs running along the floor underneath the subfloor. I will be putting my deck screws through the ribs to fasten the subfloor down, so I need to keep track of where these are. To keep the screws in a straight line, I trace a line on the subfloor along the center of the ribs. With a line running along the length of the board that represents the center of the ribs, I can ensure every screw I put through the board hits its mark.

To fasten the subfloor down, I use two drills. One to drill pilot holes, the second to screw in the deck screws. I’m using 1 1/4″ exterior deck screws for this, putting a screw in roughly every 10 inches or so.

Installing the vinyl plank floor requires a few basic tools. A tape measure, ruler and/or square, pencil, rubber mallet, flooring install kit, a jigsaw, and a miter saw. You’ll notice the vinyl planks have the underlayment attached, which is a big bonus. Many vinyl planks are like that these days, but some planks don’t have the underlayment, and it’s something else you need to buy and install.

When installing vinyl plank flooring, you need to give special consideration to the layout. Firstly, lay out your planks in the van, as many full pieces as you can. Then, center the planks in your space, so there is an even amount of gap between the planks and the walls. If the gap is only like 1-2″ on each side of the planks, then when you cut the planks for the outer edges, you’d be cutting the planks into thin strips. This not only looks bad, but the thin strips can be harder to keep in place over time. So, if you only have a thin gap between the walls and your planks, remove another plank. Center your planks, and measure your outer gaps. Now your outer planks will

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Electrical wiring

For 12v lights and outlets throughout the van, 14-gauge wire is a good choice as it can handle up to 15 amps, which is double what is needed for any one outlet. All wiring runs should be kept under 20ft to avoid amperage loss over long runs.

Marine-grade electrical components, such as Blue Sea Systems 12v Outlets, are recommended as they are more water-friendly than typical household electrical equipment. For lighting, 3w LED puck lights in the ceiling can be controlled with a dimmer switch.

Before running the electrical wiring, it is important to plan where the electrical outlets, lights, and other components will be installed, as well as how many will be needed, and what type of devices will be plugged in. This will help determine the amount of wiring required and how it should be routed.

When running wires, it is recommended to use the beams on the ceiling to keep them in place, and to use grommets to protect the wires from sharp edges when drilling through metal beams. Hollow parts of the body can also be used to route the wires, providing protection and security.

Some wiring tasks may require splicing, such as when installing shelves with multiple outlets and lights. Non-twist connectors can be used for an easy, push-in splice job. The wiring for the lights can be done in a daisy-chain fashion, connecting one wire from the power center to the first light, and then using short sections of wire to connect to the next light in the chain.

When installing 12v outlets, spacers may be needed to provide extra clearance, especially if there is limited space behind the walls. Wooden spacers can be created by smoothing the edges with a belt sander to fit the shape of the mounting plate.

For dimmer switches, it is important to follow the specific wiring instructions provided by the manufacturer.

To protect exposed wiring, junction boxes or custom wooden pieces can be used. However, it is not recommended to use wood as it may not provide adequate protection.

For charging, heavy-duty 4-gauge cables can be used to connect the DC charger to the vehicle's battery under the hood. Flexible conduit can be used to protect the cables as they are run along the roof and above the headliner. To run the cables to the engine bay, a hole can be drilled through the firewall and a plastic plug inserted to protect the cables. Finally, a fuse holder and fuse should be installed between the positive cable and battery terminal to protect the DC charger from voltage spikes.

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Heating and cooling

The Astro van's heating and cooling system is a crucial aspect of your conversion project, ensuring comfort throughout your travels, regardless of the weather. Here are some detailed instructions and considerations for designing an effective heating and cooling system:

Insulation:

Firstly, focus on insulation. It is essential to retain heat during cold weather and prevent excessive heat buildup in warmer climates. Insulation's effectiveness can vary depending on your travel destinations. If you plan to use your Astro van in colder regions, invest in high-quality insulation materials like Thinsulate by 3M. On the other hand, if your travels are mostly confined to warm climates, you may require less extensive insulation.

Heating Options:

Now, let's explore the heating options available:

  • Diesel Heaters: Diesel heaters are a popular choice among campervan enthusiasts due to their efficiency and reliability. They operate using the vehicle's diesel fuel supply, making them suitable for extended use. Diesel heaters are typically compact and easy to install, even in limited spaces. While they can be pricey, ranging from €1500 to £2000, they offer consistent heat output and efficient fuel consumption. Ensure you purchase a reputable brand and have a qualified professional install and maintain it to avoid safety hazards.
  • Gas Heaters: Gas heating systems are an affordable and efficient option. They are often compact and portable, offering flexibility in installation and use. Gas heaters can quickly generate heat and are dual-purpose, as they can also be used for cooking. However, they require careful space management and proper ventilation to avoid the risk of intoxication. Additionally, the autonomy of the system depends on the quantity of gas carried, which may require regular refills during long journeys.
  • LPG/Natural Gas Heaters: LPG (liquefied petroleum gas) or natural gas heaters are similar to diesel heaters but use natural gas for combustion. They are generally similar in cost and performance to diesel heaters but require the installation of a pressurised gas container, which takes up extra space.
  • Electric Space Heaters: Instead of installing an expensive system, you can opt for a simple portable electric heater from any hardware store. You can power it by connecting to an external AC source at campsites or parking areas. Alternatively, invest in a portable power station, like the EcoFlow Delta, to ensure energy independence. While electric heaters are power-hungry, they are a flexible and cost-effective solution if you don't plan to spend extensive time in cold places.
  • Wood-Burning Stove: Installing a wood-burning stove provides a nostalgic and romantic experience with a real, roaring fire inside your Astro van. These stoves are inexpensive, with prices ranging from £100 to £300 for a 2kW unit. Wood fuel is also cheap and readily available, but ensure you use seasoned or dry wood to avoid generating high amounts of soot and acidic tar. Keep in mind that wood-burning stoves may not be allowed at some campsites due to safety concerns.

Cooling Options:

Now, let's discuss some options for keeping your Astro van cool during hot weather:

  • Ceiling Fans: Install one or two ceiling fans to promote airflow and prevent condensation. The number of fans depends on the length of your vehicle. For a 170" van, two fans are ideal, placed over the galley and the bed. Ensure you plan your route to avoid super hot climates, as fans may not be sufficient for extreme heat.
  • Window Considerations: While vans with many windows offer a beautiful 360-view, they come at the cost of insulation. Consider reducing the number of windows, especially in the rear, to maintain better temperature control. Additionally, curtains are essential for temperature control and privacy. Insulated curtains can be expensive, but they are worth the investment, effectively controlling hot and cold air transfer through the windows.
  • Air Conditioning: If you desire a more comprehensive cooling system, consider installing an additional air conditioning unit. However, keep in mind that AC units consume a lot of power, and you will need a generator, a robust power system, or frequent access to shore power to run them.

Additional Tips:

  • Size of Your Astro Van: Ensure the heating or cooling system you choose is appropriate for the size of your Astro van. Calculate the total volume of the space you intend to heat or cool, and select a system that can efficiently manage that space.
  • Fuel Sources: Research the availability of replacement fuel sources, such as gas, diesel, and dry wood, in the areas you plan to travel. This information will influence your choice of heating system.
  • Cost of Installation and Maintenance: Consider the installation and maintenance costs of different heating and cooling systems. Basic options like wood-burning stoves have minimal installation costs, while more complex systems like gas multi-cylinder refill systems can be pricier. Regular maintenance is crucial for safety and optimal performance, so factor in these costs as well.

By carefully considering these options and tips, you can design an effective heating and cooling system for your Astro van camper trailer, ensuring comfort throughout your adventures.

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Storage

Shelving

Vertical space is essential for storage in a camper van. Building shelves above areas such as the power centre and bed can provide ample storage for clothes, hiking gear, food, and other supplies. Consider the depth of your shelves, as deeper shelves can compromise floor space. Custom-built shelves with rounded edges for comfort and safety can be constructed using tools like a compound miter saw, table saw, belt sander, and drill press.

Under-Bed Storage

The space beneath the bed can be utilised for storing tools, towels, hiking gear, and other items. Open-top baskets or trays can be used, and the right combination of bin sizes can be determined through trial and error. Blocks of wood or boards can be used to keep the bins in place, preventing them from sliding around during travel.

Netting and Shock Cord

To secure items on shelves while driving, especially on rough terrain, consider using netting and shock cord. Flexible shock cord can be stretched between nails on the side faces of the shelves to keep items in place. For larger shelves, cargo netting can be used, allowing for flexible storage of items that may protrude from the shelf, such as clothing.

Tool Storage

An aluminium tool box can be installed on top of the van for additional storage. When choosing a tool box, consider the height and ensure it doesn't make the van top-heavy. A mounting system using angle aluminium and nuts and bolts can be employed to secure the tool box to the roof rack. The tool box is ideal for storing items like jacks and tow straps that you want to keep outside of the living space.

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Towing

When considering the towing capacity of your Astro van, there are a few things to keep in mind. Firstly, the Astro van has a towing capacity of around 5,000 lbs, which remains consistent across different models and years. This capacity is for braked capacities, meaning the trailer being towed has its own braking system to assist the vehicle's brakes. Trailers without brakes will have a lower capacity.

It's important to note that the type of trailer you'll be towing will impact the towing capacity. For example, a fishing boat and trailer can weigh between 900 and 6,000 lbs, while a tent trailer typically weighs between 1,000 and 1,500 lbs.

Additionally, the weight of the Astro van itself and any cargo inside will affect the overall towing capacity. When planning to tow, ensure that the combined weight of the trailer and its contents, plus the weight of the van and its contents, do not exceed the maximum towing capacity.

To enhance the towing experience and ensure safety, consider installing a third-party towing upgrade. This can include a transmission auxiliary oil cooler, a Class III/IV hitch, a weight distribution system, Timbren SES units for improved suspension, and electric brake controllers. These upgrades can help distribute weight more effectively and improve braking performance, which is crucial when towing heavy loads.

Furthermore, the type of terrain and driving conditions will influence the towing experience. Towing in strong headwinds, uphill, or on sharp corners will require more power and put more strain on the vehicle. It is recommended to use "D" (3rd) gear when towing heavy loads and to utilise the van's tow/haul feature to allow for higher engine revs, reducing strain on the transmission.

Lastly, always refer to the owner's manual for specific towing guidelines and recommendations for your Astro van model. By following these instructions and considering the necessary upgrades, you can safely and effectively utilise the towing capabilities of your Astro van for your camper trailer project.

Frequently asked questions

The first step is to buy a van.

Some things to consider are the vehicle's capability, off-grid capacity, workstation/entertainment centre, heating source, flooring, and storage.

It is important to consider the layout of the planks to ensure an even gap between the planks and the walls. The rule of thirds should be applied when installing vinyl plank flooring to prevent warping, buckling, and gaps.

It is important to distribute weight evenly and be mindful of tongue weight, as too much weight on the roof or front of the van can make it top-heavy.

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