Building A Vw Camper Van: A Step-By-Step Guide

How to Build a VW Camper Van

Building a VW camper van is an exciting project to embark on. There are many different ways to approach this project, and the best method for you will depend on your budget, skill level, and how you plan to use your camper van. This guide will cover the basics of how to build a VW camper van, including choosing the right van, planning your layout, insulation, electrical systems, and more.

Choosing the Right VW Van

The first step in building a VW camper van is choosing the right vehicle. There are several types of VW vans that can be used for camper conversions, including the classic VW Bus, the VW Vanagon, and the newer Eurovans. Consider your budget, the condition of the van, mileage, maintenance history, engine, body condition, tires, and test drive the van to make sure it's in good working order.

Planning Your Layout

The next step is to plan your layout. Consider how you will use your camper van, how many people will be using it, whether you need a permanent or convertible bed, storage space, kitchen facilities, and electrical outlets. Draw out your ideas and test them in your van to make sure everything fits and works for your needs.

Insulation

Insulating your VW camper van is important to keep the interior comfortable in all weather conditions. There are several types of insulation materials to choose from, such as sheep's wool, rigid foam board, closed-cell spray foam, and more. Consider the R-value, breathability, cost, and ease of installation when selecting insulation.

Electrical Systems

Adding electrical systems to your VW camper van will provide power for lighting, appliances, and devices. You can choose to build your own system or purchase a portable power station. Consider your power needs, battery capacity, solar panels, charge controllers, inverters, wiring, and fuses.

Water Systems

If you plan to cook, wash dishes, or take showers in your VW camper van, you will need to install a water system. This includes a freshwater tank, pump, faucet, grey water tank, and proper plumbing. You may also want to consider a hot water heater or portable shower system.

Heating and Cooling

To keep your VW camper van comfortable in all seasons, consider installing a heating and cooling system. Options include portable heaters, air conditioners, roof fans, and window coverings to regulate temperature and airflow.

Final Touches

Once your VW camper van is functional, you can add the final touches to make it feel like home. This may include curtains, rugs, cushions, artwork, and other decorations.

Choosing a van

The first step in building a VW camper van is choosing the right van. The right van will depend on your budget, your mechanical skills, and your needs.

Budget

Before you start shopping for a van, you should decide on your budget. Vans can be purchased from a few thousand dollars to tens of thousands of dollars. You can buy a van from a dealership, a private seller, or online. Dealerships tend to be more expensive, but you are more likely to get a van that is free of serious problems.

Mechanical Skills

If you are mechanically inclined, you may want to consider an older van like a T2 Volkswagon that needs some mechanical work. If not, then a newer van that needs less work may be a better option.

Needs

You should also consider how you plan to use the van. For example, if you want to be able to stand up in your van, you will need a van with a higher roof, like a Ford Transit. If you are planning on travelling with multiple people, you will need a larger van with a longer wheelbase. If you are planning on stealth camping, you will want a van that looks more like a cargo van, like a Nissan NV or Ram Promaster.

Popular Vans for Conversion

The three most popular vans for conversion are:

• Sprinter Vans: Sprinter Vans are popular because of their reliability, size, diesel engine, and shape.
• The Ram Promaster: The Ram Promaster is popular because of its width, maneuverability, and fuel efficiency.
• The Ford Transit: The Ford Transit is popular because of its affordability and height.

Where to Find a Van

You can find a van to buy at a local car dealership, on Craigslist, or on Facebook groups.

Planning your 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 do you plan to use your van? Will you be living in it full time, part-time, or just taking the occasional road trip?
• 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 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.

Insulation

Insulating your VW camper van is crucial to keeping the van warm in the winter and cool in the summer. There are several methods and materials you can use to insulate your van, each with its own pros and cons. Here is a step-by-step guide on how to insulate your VW camper van:

Step 1: Soundproofing

Before installing any insulation, it is essential to soundproof your van to reduce noise from the outside, such as rain. Sound deadening strips are a popular choice for this purpose, as they are easy to apply and cut to size. Apply these strips to the roof and walls of the van.

Step 2: Insulating the Floors and Walls

For the floors and walls, you can use a combination of thermal insulation boards and recycled bottle wool. Insulation boards, such as Celotex, Recticel, or Kingspan, are ideal for filling large cavities in the van walls and floors. Recycled bottle wool, on the other hand, is perfect for stuffing into hard-to-reach nooks and crannies. Cut the insulation boards to size and fit them into the cavities. Then, spend time filling all the small gaps with the bottle wool, as this will help maximise the insulation in your van.

Step 3: Insulating the Bulkhead

If you have a bulkhead divider between the cab and the back of your van, you'll need to insulate this area as well. You can use a thinner insulation board for the bulkhead, such as 25mm insulation board, to save space. Build a wooden framework for the bulkhead and slot pieces of insulation into the spaces between the battens.

Step 4: Insulating the Ceiling

For the ceiling, you can use a similar approach as for the walls. First, install wooden support beams along the roof, ensuring they match the depth of your chosen insulation board. Then, if your van has ridges and troughs in the roof, you can utilise these air gaps by sticking reflective foil insulation, such as Reflectix or Low-E, to the roof. Finally, stick your chosen insulation board to the roof, using insulation stick pins or double-sided sticky tape.

Step 5: Installing a Vapour Barrier

Once all the insulation is in place, cover the entire van with a vapour barrier. This will act as a moisture barrier, preventing condensation from reaching the insulation. Use spray adhesive to hold the vapour barrier in place and tape the seams with aluminium foil tape.

Materials and Tools:

• Sound deadening strips
• Thermal insulation boards (e.g., Celotex, Recticel, Kingspan)
• Recycled bottle wool
• Vapour barrier (e.g., silver bubble foil insulation)
• Spray adhesive
• Aluminium foil tape
• Wooden support beams
• Insulation stick pins or double-sided sticky tape
• Safety gear: goggles, gloves, masks

Electrical system

The electrical system is one of the most important parts of your VW camper van conversion. It will power everything from your fridge to your lights and fan, as well as charge your electronics.

Components of a Camper Van Electrical System

There are three stages to a camper van power system: the power storage system, the electrical supply system, and the power distribution system.

Power Storage System

The power storage system is where the electricity is stored so that it can be used to power your appliances and devices. This is typically a leisure battery or a battery bank, which is separate from the vehicle's main battery that is used to start the engine.

There are several types of leisure batteries available, including flooded lead-acid, gel, AGM (Absorbent Glass Mat), and lithium-ion batteries. The type of battery you choose will depend on factors such as your budget, the size and capacity you need, and how long you plan to use your camper van.

When choosing a leisure battery, consider the amp-hours (Ah) or the amount of charge the battery can deliver in one hour. A higher Ah rating means the battery has a higher capacity and can power devices for a longer period.

Electrical Supply System

The electrical supply system is how you create the initial power for your camper van. There are three common methods: a split charge system, a solar power system, and shore power.

#### Split Charge System

A split charge system charges your leisure battery from your vehicle's primary electrical system. It consists of a heavy-duty power cable, terminal connectors, and a split charge device that acts as a switch to control the flow of power.

There are several types of split charge devices, including manual switches, 12V relays, and voltage sensing relays (VSRs). VSRs are recommended as they can intelligently monitor the incoming voltage and only allow power to flow when the conditions are right.

#### Solar Power System

A solar power system uses solar panels to generate electricity from sunlight. It typically consists of solar panels, solar cables with MC-4 connectors, a solar charge controller to regulate the voltage/current, a fuse for safety, and a leisure battery to store the electricity.

Solar power is a great way to generate electricity when you're off-grid, but it may not be reliable in cloudy or winter conditions.

#### Shore Power System

Shore power, also known as hook-up power, allows you to connect your camper van to a land-based power source, such as a power inlet at a campsite. It consists of a power inlet, a consumer unit/breaker panel, a battery charger, and connecting wires.

Shore power provides a convenient and guaranteed power supply but requires you to remain in a fixed location.

Power Distribution System

The power distribution system is how you deliver the power to your appliances and devices. You can choose to install either a 12-volt system, a mains voltage system, or both, depending on the voltage of the appliances you intend to use.

#### 12-Volt System

A 12-volt system is ideal for low-power appliances and devices, such as LED lights and USB charge sockets, that run off 12-volt power. It is relatively simple to install as it works independently from your camper van's native 12-volt electrical system.

To connect your appliances, you can install a fuse box, which provides multiple 12-volt connection points. You will also need a bus bar, which is a positive and negative terminal that helps keep your installation clean and simple.

#### Mains Power System

A mains power system is used to power high-voltage appliances such as hair dryers, microwaves, and TVs. It can be achieved through a power inverter or shore connection.

##### Power Inverter

A power inverter changes the 12-volt direct current (DC) power from your leisure battery into conventional mains alternating current (AC) power (usually 110V or 230V). It is connected to a consumer unit, from which socket outlets are installed in your camper van.

##### Shore Connection

A shore connection involves connecting your camper van to a land-based power source via a power inlet and a special connection cable. The electricity then passes through a breaker box and is delivered to power outlets in your camper van.

Sizing Your Electrical System

When designing your electrical system, it's important to consider your power needs and how you will use your camper van. Calculate the total amp-hours (Ah) or watt-hours (Wh) of electricity you will use per day, taking into account all the appliances and devices you plan to use.

Based on this calculation, you can determine the size of your leisure battery, solar panels, battery charger, and inverter. It's generally recommended to have at least three days' worth of power without charging.

Camper Van Electrical System Example

• Fogstar Drift PRO 460Ah - 12V lithium leisure battery
• Victron Battery to Battery Charger 30A - 12/12 Orion-Tr Smart - Non-Isolated DC-DC Charger
• Victron MPPT 100/50 - SmartSolar Charge Controller
• Victron 500VA Inverter 12V - Pure Sine Wave Phoenix Inverter VE.Direct
• 12V Fuse Box - Blue Sea - 12 Circuits with Negative Bus and Cover
• Victron BMV-712 Smart Battery Monitor

Plumbing

Planning Your Plumbing System

Before you start installing the plumbing in your VW camper van, it's essential to plan and choose the components that best suit your needs. Consider the following:

• Water Tanks: Decide on the size and placement of your freshwater and greywater tanks. Freshwater tanks store potable water, while greywater tanks collect wastewater from activities like washing dishes or showering. You can opt for detachable or fixed tanks, with the latter offering more capacity but requiring a more complex installation.
• Water Pump: Choose between a manual or electric water pump. A manual pump is cheaper and easier to install but may be more strenuous to use. An electric pump offers the convenience of pressurised water but adds complexity to your electrical system.
• Sink and Faucet: Select a sink that fits your counter space and cabinet height. Consider whether you want an undermount or drop-in sink, the number of holes for accessories, and the layout of your counter. For the faucet, decide on the height and whether you prefer a single handle or separate hot and cold water handles.
• Hot Water System: If you want hot water for showers or washing dishes, consider installing an LPG tankless water heater, a water boiler, or a hydronic heating system. These options vary in cost, complexity, and fuel type.

Installing the Plumbing System

Once you've gathered the necessary components, it's time to install your VW camper van's plumbing system:

• Mount the Water Pump: Securely mount the water pump in your desired location, typically near the freshwater tank.
• Connect the Water Pump and Filter: Use clear braided tubing and hose clamps to connect the water pump to the freshwater tank and the water filter. Ensure all connections are secure and use plumbing tape on threaded connections.
• Attach the PEX Pipe: Connect the PEX pipe to the water filter coupling using plumbing tape on the threads.
• Connect Hot and Cold Water Lines: Attach the hot and cold water lines from the faucet to the threaded male ends of the PEX coupling.
• Mount the Water Filter: Mount the water filter and connect the supplied hoses to the filter coupling and inlet.
• Connect the Filter Water Line: Run the hose from the filter faucet to the outlet side of the filter.
• Connect the Grey Water Tank: Use a flexible drain trap hose system to connect the sink drain to the greywater tank, ensuring you use plumbing tape on the threads.
• Power the Water Pump: Wire the water pump to your power source and test the system for leaks.

Additional Considerations

• Accumulator: Install an accumulator after the water pump to smooth out pressure changes and provide a better water usage experience.
• Water Pickup Tube: Instead of using pre-made holes in the freshwater tank, consider drilling a hole in the top and installing a DIY water pickup tube to draw water from the bottom. This reduces the risk of leaks and ensures you utilise all the water.
• Points of Use: Try to locate all water points of use (faucets, shower, etc.) on one side of the van to simplify plumbing routing.
• Water Tank Placement: Place the water tank over an axle to distribute the weight efficiently.
• Water Filtration: Use an inline water filter to ensure clean and safe water, especially when filling up from various sources.
• Fill Ports: Consider adding a fill port with quick connects for easier refilling, or an access hatch for simpler refilling through the top of the tank.
• Winterisation: If you plan to use your van in cold temperatures, winterise your water system by draining all tanks and lines, removing water filters, and adding non-toxic antifreeze if necessary.

Frequently asked questions