Transforming Vans: Diy Guide To Camper Conversion

Converting a van into a campervan is a rewarding experience, but it can be challenging and time-consuming. Here is a step-by-step guide to help you through the process.

Step 1: Set a budget

Before starting your conversion, decide on a budget and try to stick to it. Converting a van can be expensive, with costs ranging from £3,000 to £10,000 or more, depending on the level of customisation and professional help required. Remember that a well-converted van is likely to retain its value.

Step 2: Find your van

The next step is to find a suitable van for conversion. Consider your budget, desired features, and intended use. Popular options include the Peugeot Boxer, Fiat Ducato, Citroen Relay, Mercedes Sprinter, Ford Transit, and Renault Trafic.

Step 3: Design your layout

Spend time planning the layout of your van. Consider your needs, such as the number of beds, kitchen facilities, storage space, and windows. Sketch out your design or use online tools like VanSpace to create a detailed plan.

Step 4: Buy equipment and materials

Purchase the necessary equipment and materials, including tools, insulation, cladding, electrical components, and furniture. Order in advance to avoid delays and store them safely.

Step 5: Cut holes and install windows

Cut holes in the van for windows, skylights, and roof fans. Measure twice and cut once to avoid mistakes. Use masking tape to protect the paintwork and wear protective gear.

Step 6: Install seats (optional)

If desired, install additional seats to accommodate more passengers. Ensure that the seats are securely fitted and comply with safety regulations.

Step 7: Lay the floor

Insulate the floor using materials like Celotex or Kingspan insulation boards, and cover with plywood and vinyl flooring. Ensure a level surface and consider the weight distribution.

Step 8: Build the frame

Construct a structural frame using wooden battens and plywood. This will provide support for the walls, cabinets, and other fixtures.

Step 9: Install electrics

Consult a qualified auto electrician to install your electrical system. Decide on the type of batteries, charging methods (solar, electric hookup, etc.), and appliances you need.

Step 10: Insulate the van

Insulation is crucial for maintaining a comfortable temperature. Use a combination of insulation board and loose-fill polyester wool. Cover with a vapour barrier, such as aluminium foil bubble wrap, to prevent condensation.

Step 11: Clad the walls

Cladding options include thin plywood sheets or strips of cladding, which can be painted or varnished. Consider the aesthetics and your personal preference.

Step 12: Build internal structures

Using wooden battens and plywood, construct beds, kitchen cabinets, storage spaces, and other desired features. Measure and plan carefully before building.

Step 13: Install water and gas systems

Decide on the complexity of your water and gas systems. You can opt for simple solutions like a jerry can and a portable stove, or go for more advanced setups with multiple appliances. Ensure proper installation and engage a GasSafe engineer for checks.

Step 14: Add finishing touches

Personalise your van with decorations, curtains, plants, and other touches to make it feel like home.

Step 15: Submit for reclassification

Once your conversion is complete, submit the necessary paperwork to the DVLA to reclassify your vehicle from a van to a motorhome. This may affect your insurance and MOT requirements.

Budgeting and planning

Know your budget

First, decide on a realistic budget and stick to it. Converting a van can be expensive, with even the cheapest of conversions running close to £10,000. Larger vans and more complex conversions requiring extensive metalwork or welding can quickly increase in price. It's important to be aware of your financial limits and plan accordingly.

Choose the right van

When choosing a van, consider your intended use and budget. Vans come in a variety of sizes, so select one that fits your needs. If you plan to transport multiple people, ensure each occupant has a proper seat and an M1-tested seatbelt. Forward-facing seats are more comfortable and safer than side-facing ones.

If you're looking for a van that's easy to drive and park, consider a smaller option like the Volkswagen Transporter. Larger vans, such as the Mercedes Sprinter or Fiat Ducato, offer more interior space but may be more challenging to manoeuvre.

Plan your layout

Consider how you will use your van. Will you be living in it full-time or just taking occasional road trips? How many people will be using it? What type of cooking facilities do you need? Do you require a shower and toilet? Answering these questions will help you design a layout that suits your needs.

Ventilation and insulation

A proper ventilation system is crucial to maintain a comfortable environment inside the van. It will help remove water vapour and heat, making the cabin more pleasant. If you plan to install a shower and bathroom, ensure the ventilation system is comprehensive to prevent moisture buildup.

Don't skimp on insulation, especially if you'll be travelling in chilly climates. Proper insulation will make your van more comfortable and reduce night-time noises. Consider adding sound deadening materials for an even quieter ride.

Fresh and waste water storage

If you plan to install running water, think about how you'll store fresh and waste water. The number of appliances you install will affect the size of your water storage tanks. You can use either external portable containers or fixed internal tanks, with the latter being the most popular option.

Furniture and fittings

Consider your comfort and create a space that feels like home. You can build custom furniture to perfectly fit your van or opt for pre-built units if you're not confident with tools. Don't forget to include storage solutions to keep your van organised and clutter-free.

Timescale and professional help

Campervan conversions often take longer than expected, so set a realistic timescale to avoid undue pressure. Hiring a professional can speed up the process, but be aware that conversion specialists are in high demand and you may have to wait.

If you're feeling overwhelmed, consider purchasing a ready-made camper van. While it may be more expensive, it will save you time and ensure a consistent level of quality. With a custom build, you have the freedom to tailor the van to your exact needs and choose your own materials and appliances.

Choosing a van

Budget

First, you need to decide on a budget. Converting a van into a camper can cost anywhere from £3,000 to £10,000 or more, depending on your skill level, tools, and materials. Keep in mind that a well-converted van is unlikely to lose money, as campers retain their value in the used market.

Purpose

Next, consider what you need from your camper. Will you be using it for off-grid camping or mostly at campsites? Do you need a shower and toilet, or will you have access to facilities? Do you need solar panels for off-grid power? How many beds and seats do you require, and do they need to be forward-facing for safety and comfort? Answering these questions will help you design your layout and choose the right van.

Size

Vans come in various sizes, so select one that suits your needs. Larger vans offer more space but are more expensive to run and may be challenging to park and store. Smaller vans, like the Volkswagen Transporter, are easier to drive and live with daily but provide less interior space.

Base Vehicle

When choosing a base vehicle, consider ex-fleet vans, as they tend to have regular services and sensible mileage. Popular options include the Peugeot Boxer, Fiat Ducato, Citroen Relay, Mercedes Sprinter, Ford Transit, and Renault Trafic. The Sprinter and Transit are pricier but offer more headroom and are ideal for custom builds. The Ducato and Trafic are spacious but narrower, making them easier to manoeuvre.

Time Commitment

Converting a van can take months or even years, depending on your skills and available time. If you're short on time, consider hiring a professional or buying a ready-made camper.

Tools and Space

Converting a van requires various tools, such as clamps, jigsaws, screwdrivers, impact drivers, electric drills, tape measures, mitre saws, and multi-tools. Ensure you have access to these tools and a suitable workspace, such as a garage or workshop, before starting your project.

Safety and Regulations

Finally, keep safety and regulations in mind. All seats must have seat belts, and gas and electrical installations should be done by professionals or checked by them afterward. Ensure your conversion meets weight limits and doesn't exceed the van's load-carrying capacity. Re-register your van with the DVLA as a "motor caravan" to enjoy benefits like lower insurance costs and higher speed limits on dual carriageways.

Insulating and ventilating

Step 1: Buy the Correct Tools and Materials

Don't skimp on insulation materials. This is the part of the camper conversion that will keep you warm and create a cosy and quiet atmosphere in your tiny home. You will need insulation boards such as Kingspan and Celotex, aluminium tape, loft insulation (glass mineral wool), ThermaWrap (general-purpose insulation), cladding/plywood, and softwood beams.

Step 2: Clean Your Camper

Clean your van thoroughly and check for any cracks, holes, or rust that need attention before you start adding insulation. This will help you familiarise yourself with the shape and structure of your van.

Step 3: Plan Your Electrical System

Before installing insulation, plan your electrical system, including lighting, energy usage, and plug placement. Feed cable conduit through the metal frame of your van for household electric plug wires and solar wire. Install any solar panels on the roof.

Step 4: Make Window and Roof Cut-Outs

Install windows, roof vents, or chimneys before adding insulation to avoid cutting through insulation and wasting material. Wait a few days after installation to ensure there are no leaks, which could damage your insulation.

Step 5: Install Sound Deadening

Add sound deadening material to the metal floor of your cab area to reduce noise while driving. You can also use it on the ribbed floor of your van to level out the surface.

Step 6: Install Van Floor Insulation

If your van has an existing wooden floor, lift it up to check the metalwork underneath and make any necessary repairs. Create a softwood pine beam frame on the floor, forming a grid. Fill the grid with cut-to-size insulation boards, add expanding foam if needed, and tape over any gaps with aluminium foil. Finally, reattach your floor by screwing it onto the pine beam frame.

Step 7: Add ThermaWrap Insulation

Attach ThermaWrap to the metal walls of your van using spray adhesive and cover any gaps with aluminium tape. ThermaWrap, with its reflective foil, reduces thermal energy loss from your van.

Step 8: Install the Rib Cage

Build a rib cage with softwood beams to hold your insulation and cladding in place. Measure the height of your van and the width of the metal ribs. Drill pilot holes in the wood, push against the metal ribs, and attach with screws. The rib cage will also serve as anchor points for cupboards and storage.

Step 9: Install Your Cladding and Insulation

Place a piece of cladding against the rib cage at the bottom of your wall and drill a hole through it into the wooden beam. Screw the cladding into place and repeat until you have attached four to five boards. Then, fill the gap between the cladding and ThermaWrap with glass mineral wool insulation. If using insulation boards, cut them to size, attach with spray adhesive, and fill gaps with expanding foam. Cover with aluminium tape and cladding or plywood.

Step 10: Finish Off with Expanding Foam

Fill any remaining gaps or exposed edges with expanding foam. Be careful not to block areas of cable conduit. You can cover exposed edges with lengths of rope for a tidy finish.

Ventilation

In addition to insulation, proper ventilation is crucial to prevent condensation and moisture buildup in your van. Here are some tips for ventilating your campervan:

• Install a roof vent or fan to allow air circulation and prevent condensation.
• Ensure you have ample ventilation by having at least one air inlet and one air outlet, such as a fan and a sliding window.
• Consider installing a floor vent to bring in cool air from under the van during the summer months.
• Use a dehumidifier to reduce moisture levels, especially in cold and wet months.
• Keep your van warm to help control moisture. A heater with a low setting can be left on during cold and wet months to maintain a comfortable temperature.

Installing electrics and gas

Electric system

The electrical system is one of the most daunting parts of a van conversion. It is also one of the most expensive parts of a van build, and there are a lot of different factors to consider. You will need to decide whether you want to opt for AGM or lithium leisure batteries, what size battery bank you need, how you will recharge them (solar power, electric hookup, whilst driving using a battery to battery charger, or a mixture of the three), and whether or not you need to install an inverter to provide 230V power.

Lithium batteries are the best choice for modern campervans. They last much longer, charge faster, and can be fully discharged without damage. Battle Born batteries are made in the US, and designed specifically for mobile living and off-grid dwellings.

Before you install your electrical system, it is important to have a diagram of where each component will be. Each product will be connected to the system using the relevant thickness cable, and all components will be connected to a central negative and positive busbar, which in turn are connected to the leisure batteries. All products should be correctly fused to protect both them and the leisure batteries from any current spikes.

If you’re worried about tackling the electrics yourself, you can always outsource it to a professional. There’s no shame in getting some help if it enables you to make your campervan dreams a reality.

Gas system

Installing the gas system can be a big headache. It is recommended to bring in a trained gas engineer to advise you when fitting gas appliances and then to check your system afterwards. Not only will it save your life, but it will also mean you don’t run into any insurance issues if a few months down the line your van burns down because you installed something incorrectly.

All appliances need to be “hard plumbed”, meaning they are connected with copper pipe (usually all 8mm). All fittings should be compression fittings. If you have a gas bottle inside the van, then it needs to be inside of a sealed locker space with a drop vent in the ground. Most other gas appliances (e.g. air heater and water heater) need to be in a sealed unit with a drop vent through the chassis as well.

Adding furniture and storage

• Bedding and seating: A campervan isn't really a true campervan unless it has its own bed, and there are many routes you can go down here. If you're looking to save space, consider a bed that neatly folds away during the day. If you're after something more permanent, a fixed bed with storage underneath is a great option. If you're converting a van with a high roof, you could even consider a double bed above a seating area.
• Storage: When it comes to storage, you can get creative. For example, you could use the space underneath your bed for clothes, camp chairs, and other large items. Clear plastic containers are great for this. You could also use the space behind the driver's seat for a behind-the-door organiser to hold kitchen supplies, or hang a laundry bag or shoe rack from the ceiling.
• Tables and kitchen counters: If you're planning on cooking inside your van, you'll need a kitchen counter with a sink and a stove. You could also add a table that can double as a dining table and a workspace.
• Other furniture: Depending on your layout, you might want to add a couch or some chairs. If you're handy with tools, you could even build a custom piece of furniture that fits your space perfectly.

Frequently asked questions