Transforming Enclosed Trailers Into Cozy Campers

how to make a camper from an enclosed trailer

Converting an enclosed trailer into a camper is a great way to get into the RV lifestyle without breaking the bank. It is a wonderful way to keep costs down while constructing a unique trailer built to meet your needs. You can start with a cargo trailer designed for hauling personal items, and then add materials, appliances, and furniture.

A cargo trailer conversion is a particularly great option if you’ve scoured every RV show and dealership in the area and are struggling to find your dream RV. It is a more customizable, cost-effective, and lightweight alternative to traditional RVs.

There are many benefits to building your own camper trailer compared to purchasing a travel trailer. Firstly, it will be a lot cheaper. You can buy a brand new enclosed cargo trailer for under $3000, whereas travel trailers start at a minimum of $10,000 and can go up to $60,000. Even an old used travel trailer will probably cost more than a brand new high-quality box trailer that you can remodel to your exact design.

Additionally, you can insulate and spec out a cargo trailer conversion to a higher standard. Often, professional travel trailer manufacturers build to lesser standards than you might prefer. They anticipate that you will use the travel trailer in an RV park with electric hookups, so they don't always include the best insulation. With a cargo trailer conversion, you can install a high-spec solar system and go off-grid.

Another benefit of a cargo trailer conversion is that it will be more durable and last longer. Aluminum cargo trailers are built to last and are simple to repair. If you do the conversion yourself, you will learn how everything works and be able to fix any small issues without paying for expensive repairs.

Converting an enclosed trailer into a camper is a fantastic option for those looking to get into the RV lifestyle on a budget. Not only will it be cheaper, but you can also customize it to your exact specifications and needs. So, if you're handy and looking for a fun project, why not give it a go?

Characteristics Values
Purpose Camping, hunting, stealth camping, off-grid living, travelling, housing the homeless, etc.
Cost $7,000-15,000 for a conversion, $3,000 for a new cargo trailer, $10,000-60,000 for a travel trailer
Weight Lightweight, weigh less than travel trailers, save on gas money
Durability More durable than travel trailers, simple to repair, last longer
Customisation Customisable, versatile, can be used for multiple purposes, can be built to your exact design
Time Conversion projects can take anywhere from a month to a couple of years

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Electricals: solar panels, batteries, and lighting

Solar panels, batteries, and lighting are key components of your camper trailer's electrical system. They will provide power for various devices and appliances, enabling you to enjoy modern conveniences while camping off-grid. Here's a comprehensive guide to help you set up these electrical aspects of your camper trailer:

Solar Panels:

Solar panels are essential for harnessing sunlight and converting it into electricity to power your camper trailer's electrical system. When choosing solar panels, consider the following:

  • Size and Number: The rule of thumb is that the more solar panels you have, the faster you can generate electricity. If you plan to have more than four solar panels, ensure you get a compatible charge controller.
  • Installation: Mount the solar panels on the roof of your trailer. Try to angle them towards the sun for optimal energy capture.
  • Wiring: Run wires from the solar panels into the trailer and connect them to the charge controller. Use existing wire ports if possible (e.g., refrigerator vents, plumbing pathways) to avoid drilling holes. Drill holes only if necessary and make sure to caulk them to prevent leaks.

Charge Controller:

The charge controller is a crucial component that regulates the voltage coming from the solar panels, ensuring the battery bank receives the power it needs without overcharging. Here's what you need to know:

  • Function: It controls the speed and amount of charge going into the battery bank, preventing overcharging and battery damage.
  • Placement: Mount the charge controller inside the trailer, preferably close to the battery bank to minimize wire length.
  • Wiring: Connect the wires from the solar panels to the charge controller, following the manufacturer's instructions.

Inverter:

The inverter is responsible for converting the 12-volt DC power from the battery bank into 120-volt AC power, which is needed to operate certain appliances like your fridge, TV, and coffee maker. Here's what you should know:

  • Function: It transforms the battery's DC power into AC power, allowing you to use a wider range of devices and appliances.
  • Placement: Install the inverter near the batteries, away from heat sources or corrosive substances. Follow the manufacturer's instructions for proper installation.

Batteries:

The batteries, or battery bank, are the heart of your electrical system, storing the captured solar energy for use when needed. Here are the key considerations:

  • Types: There are three main types of batteries: LifePO4 Lithium, AGM (Lead Acid), and Flooded Cell (Lead Acid). LifePO4 Lithium batteries, such as those from Dakota Lithium, offer superior performance and longer power duration.
  • Storage Capacity: Determine how much storage you need based on your power requirements. Calculate the watt-hours of your devices and appliances, and ensure your battery bank can provide sufficient power for the duration of your trips.
  • Placement: Install the batteries securely, following manufacturer guidelines. Ensure they are well-ventilated and protected from extreme temperatures.

Lighting:

LED lights are a popular choice for camper trailers due to their energy efficiency and longevity. Here are some tips for lighting:

  • Efficiency: LED lights consume minimal power and last a long time, making them ideal for off-grid camping.
  • Placement: Consider your lighting needs and place lights accordingly. You may want lights near sleeping areas, the kitchen, and exterior entrances.
  • Wiring: Run electrical wiring to designated light locations and connect them to the electrical system. Ensure all wiring is correct in terms of polarity (positive and negative).

In summary, setting up the electrical system in your camper trailer involves installing solar panels, a charge controller, an inverter, batteries, and lighting. Each component plays a crucial role in ensuring you have a reliable power source during your camping adventures. Remember to follow safety guidelines and consult professionals if you have any doubts about the installation process.

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Insulation and windows

Insulating your trailer is crucial for ensuring comfort and efficiency while camping in different weather conditions. Proper insulation helps regulate the interior temperature, keeping you warm in cold weather and cool during hot summers. It also reduces condensation, minimises energy consumption, and improves overall energy efficiency.

Evaluating Current Insulation

Firstly, check if your trailer already has some insulation. Older trailers might have little to no insulation, while newer ones may have basic insulation. Knowing the existing situation will help you plan better.

Choosing Insulation Material

There are various insulation materials to choose from, each with its pros and cons. Some common options include:

  • Fiberglass: Easy to install, affordable, and widely available. Comes in rolls or batts.
  • Rigid Foam Board: Offers high R-value (thermal resistance) and moisture resistance.
  • Spray Foam: Provides excellent coverage and fills gaps effectively, but can be more expensive.
  • Reflective Foil Insulation: Works well to block radiant heat and is lightweight.

Preparing the Trailer

Remove any furniture or fixtures that may obstruct access to the interior walls and ceiling. Clean the walls and ceiling to ensure the insulation adheres properly. Before adding insulation, check for any gaps, holes, or cracks where air might seep in or out. Use caulk or expanding foam to seal these areas to improve the overall effectiveness of the insulation.

Insulating the Ceiling

For fiberglass or foam board, measure and cut the insulation to fit between the ceiling joists. Spray foam can also be used for ceiling insulation but be mindful of excess weight if you have a pop-up or lightweight camper. Reflective foil insulation can be attached to the ceiling using adhesive or staples.

Floor Insulation (Optional)

If desired, you can insulate the trailer's floor for added comfort. Rigid foam board or fiberglass insulation can be placed between the floor joists. Seal any gaps around the edges of the floor with weather-stripping.

Insulating Windows and Doors

Insulate windows by using thermal curtains or window insulator film to reduce heat transfer. Weather-stripping can be applied to seal gaps around doors and windows.

Ventilation Considerations

While insulation is essential, proper ventilation is equally important to prevent condensation and allow fresh air circulation. Install vents or exhaust fans to promote airflow.

Electrical and Plumbing

If you have electrical wiring or plumbing running through the walls, consider using foam board or spray foam to insulate around them without blocking access.

Testing and Monitoring

Once the insulation is in place, test your trailer in different weather conditions to see how well it performs. Monitor the interior temperature and address any issues that may arise.

Finishing Touches

After insulation, you can reinstall furniture and fixtures, keeping in mind not to compromise the insulating layers. Consider using insulating materials for curtains or blinds to further improve temperature regulation.

Installing Windows

Windows are a necessary part of any cargo trailer camper. They make the space airier and allow you to enjoy the view outside. Here are the steps to install windows in your trailer:

  • Plan the Window: Decide on the size, type, and placement of the window.
  • Make a Frame: Build a wooden frame from square-shaped timber. This will make it easier to fit the window and provide support.
  • Cut Out the Window Opening: Use the wooden frame to mark the placement and size of the window on the inside of the trailer. Drill small holes in the corners of the outline to guide you as you cut through the outline from the outside. Use a jigsaw to cut through the wall.
  • Install the Window: Seal the edges of the opening with rust-proofing primer and sealant. Attach the wooden frame to the opening using adhesive and screw clamps to keep it in place temporarily. Position the window inside the frame and screw it in. Use elastic sealant on the outside to seal the window.
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Plumbing and HVAC

Planning and Research:

Before you begin, it is crucial to thoroughly research and plan your plumbing and HVAC systems. This includes understanding the basic components of a plumbing system, such as a freshwater tank, water pump, accumulator, grey water tank, tubing, and connectors. Additionally, consider the type of HVAC system you want, such as a mini-split system or a roof-mounted fan. Researching and planning will help you make informed decisions and avoid costly mistakes.

Plumbing System Installation:

  • Water Tanks: Install a freshwater tank to store potable water and a grey water tank to catch used water. Consider the size and shape of the tanks to maximise space efficiency. For example, an "over the wheel well" water tank centres the weight of water over your axle and saves space.
  • Water Pump and Accumulator: Install a 12V water pump to pressurise your water system. Connect it to a water pickup tube that draws water from the bottom of the freshwater tank to reduce the risk of leaking. Install an accumulator after the water pump to smooth out pressure changes and create a better water usage experience.
  • Plumbing Lines and Fittings: Use flexible water piping such as braided vinyl tubing or PEX tubing to connect all your tanks and components. PEX tubing is more durable and has a higher burst pressure rating, making it ideal for cold temperatures.
  • Points of Use: Decide on the fixtures you will be using water from, such as showers, sinks, or outdoor sprayers. Try to locate these fixtures on one side of your camper van to simplify the plumbing installation.
  • Grey Water Management: Determine how you will dump your grey water. You can use jugs under the sink that you empty responsibly, or install a permanently mounted grey water tank with a ball valve for easier drainage.
  • Water Filtration: Install an inline water filter to ensure water quality, as you will be filling your tank from various sources. Consider adding a UV water purifier at your point of use for extra confidence.
  • Fill Ports: Decide how you will fill up your water tank. You can use an access hatch or create a fill port with quick connects. If you choose the latter, install an "overflow" valve to know when your water tank is full.

HVAC System Installation:

  • Mini-Split System: If you opt for a mini-split HVAC system, wait to install it until after you've finished the walls. Start by roughing in all the connections to ensure they fit, then hook up the pipes and connect them to your water tanks. Run your ducts and vents, and finally, install and test the unit.
  • Roof-Mounted Fans: Many camper vans use roof-mounted powered fans, such as the MaxxFan or Fantastic Fan, to provide forced ventilation. Combine these with passive cooling methods, such as choosing a reflective paint colour, insulating the van well, and providing windows and vents for air circulation.
  • Evaporative Cooling: Evaporative cooling uses the evaporation of water to cool the air and can be very effective in low humidity conditions. Commercial units like TurboKool can cool an insulated camper van efficiently and are powered by solar and batteries.
  • Air Conditioning: If you require air conditioning, consider the power source and efficiency of the unit. Traditional air conditioners require shore power or a generator, while more efficient options like DC-powered mini-splits or adapting window air conditioners can run on solar and batteries.
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Framing and flooring

Framing:

Before starting, ensure you have a clear plan and the necessary materials and tools. Lay the trailer frame on a level surface. Begin by assembling the perimeter of the base frame using long beams, connecting them with corner brackets or welding. Insert cross beams at regular intervals for added support and fasten them securely, ensuring they are perpendicular to the perimeter beams. Use heavy-duty materials like steel to withstand travel rigours and the weight of your camper.

Double-check alignment with a laser level or plumb line, and ensure equal spacing between cross beams. Reinforce stress points, such as where the axle meets the frame and the towing mechanism, with angled braces for even weight distribution. Your frame should be robust and true under pressure.

Flooring:

There are several options for flooring your camper, but it's essential to choose a waterproof, easy-to-install, low-maintenance, and lightweight material. Luxury Vinyl Plank (LVP) flooring is a popular choice, offering a waterproof, durable, and DIY-friendly solution. It comes in long strips, snapping together without glue, and floating on the floor.

Here's a step-by-step process for installing LVP:

  • Clean the subfloor section-by-section with a degreasing cleaner. This ensures proper adhesion of the vinyl planks.
  • Dry-fit a piece of vinyl plank to ensure the pattern works with your layout.
  • Apply glue to the back of the plank. Use a wavy line across the entire back to ensure adhesion.
  • Press the plank firmly in place and step on it to secure it.
  • Continue laying the flooring until the entire surface is covered.

If you have a slide-out section in your camper, you'll need to make some adjustments:

  • Overlap the vinyl planks about 1" off the edge of the slide-out toward the main camper.
  • Work your way outward, placing planks on the bare plywood flooring.
  • Use a paper template for accurate cuts around weird corners.
  • Add reducer trim to create a finished look and cover any plastic edging.
  • You can also add quarter-round trim along the base of walls and cabinets for a clean transition from flooring to wall.

With these steps, you'll have a sturdy frame and a functional, aesthetically pleasing floor for your camper!

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Finishing touches: decor, appliances, and furniture

Now that the heavy lifting is done, it's time to add the finishing touches to your camper. Here are some ideas for decor, appliances, and furniture to make your camper feel like home:

Decor

  • Paint the walls to add a splash of colour and make the space your own.
  • Add some carpet to keep your feet warm and make the space feel more homely.
  • Put up some curtains or blinds for privacy and to block out light when needed.
  • Install some lighting, such as LED lights or fairy lights, to create a cosy atmosphere.
  • Hang some artwork or photos to make the space feel more personal.
  • Bring some cushions and blankets to make the space more comfortable and inviting.

Appliances

  • Install a simple sink with a garden hose attached to a shelf for brushing your teeth and washing up.
  • Set up a small fridge or cooler to keep your food and drinks cold.
  • Add a hot plate or portable stove for cooking meals.
  • Invest in a portable toilet or composting toilet for convenience.
  • Bring a portable shower or use a solar shower bag for a warm shower outdoors.
  • Get a small heater to keep you warm during colder months.
  • Install a fan or air conditioning unit to keep you cool during hot weather.

Furniture

  • Build or buy a bed that can fold up against the wall to save space.
  • Add a table and chairs for eating and playing games.
  • Put in some storage cabinets or shelves to store your belongings.
  • Hang some hooks for towels, coats, or bags.
  • Bring some camping chairs and a small table for outdoor use.

Frequently asked questions

There are many benefits to converting a cargo trailer into a camper. It will be a lot cheaper, you can insulate and spec out to a higher standard, it will be more durable and last longer, it will weigh less and you'll get better gas mileage, you'll be able to take it off-road, it's a blank slate, cargo trailers hold their value and you'll add value by converting, you'll save money on repairs, a cargo trailer is more stealthy, and your trailer can be useful for many purposes.

When choosing the right cargo trailer, consider size, weight capacity, and construction quality to ensure a solid foundation for the conversion.

First, plan your cargo trailer conversion layout. Then, execute your cargo trailer camper conversion.

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