
How to Make a Homemade Camper Van
Converting a van into a camper is a rewarding project. You get to design and build your own unique living space. When you hit the road in your custom camper, you can experience van life and explore the world on your terms. However, one size does not fit all when it comes to van life. Conversion van layouts come in all shapes and sizes, and there is no single perfect van build for every individual.
Step 1: Decide on your budget and choose your van
Before you start creating your campervan layout, it's essential to think about how you plan to use the space and how many people will be using it. This will determine which campervan layouts are suitable for your van and your van life.
Step 2: Gut and clean the van
Chances are that if you are buying an inexpensive used van, there will be some initial work to do to get it all cleaned out.
Step 3: Take measurements of your van
The next step is to measure everything in your car: length, width and height obviously, but also take measurements of the wheel wells and the windows. Also, many cars bow out slightly so the width will vary from the floor, to the centre, to the ceiling. Getting all the measurements will make the next steps as simple as possible.
Step 4: Make a plan for your campervan layout
Now it's time to design your dream campervan layout. Ask yourself what is important to you in a camper van. Our advice when building a budget campervan is to keep things as simple as possible and separate your wants from your needs.
Step 5: Build the components of your van
This is where you'll get to work with your hands (and get them dirty, if you're doing it right!). With the measurements of the van, you can create a bed platform, kitchen counter and storage space using plywood, 2x4's and 2x6's.
Step 6: Make your own privacy curtains
When you're living in a camper van, you'll want some privacy. Trust me. You'll also need curtains to keep out the lights when you're trying to sleep. Making your own curtains can seem like a daunting task, but it's not all that hard.
Step 7: Make the van functional to live in
When you're living in a camper van, there are some things you'll want to think about before hitting the road. Here are some things to consider:
- How to charge electronics
- How to light up your camper at night
- How to do laundry on the road
- How to keep cool when it's hot
Step 8: Buy campervan essentials
Now that most of the hard work is done with the van build, you're going to need to make a list of all the campervan essentials you'll need to make your campervan a livable space.
Step 9: Campervan organisation
Without organisation, living in a DIY van can feel cluttered and chaotic, so you'll want to make the most of your space. This is a good time to make sure you've paired down your belongings to a reasonable amount and to make sure everything has a place.
Step 10: Final touches to make the van feel like home
This is where you can add all the little touches that make your DIY van feel like home.
Characteristics | Values |
---|---|
Budget | $2000-$20,000 |
Van | Sprinter Vans, Ram Promaster, Ford Transit |
Stand-up height | High roof |
Number of people | 1, 2, family |
Stealth camping | Yes/No |
Work on van | Yes/No |
Layout | Bed, kitchen, storage, bathroom, workspace |
Power | Solar panels, power station, car inverter, tap lights, headlamps |
Water | Water tank, shower, sink, filtration system |
Gas | LPG canister, Chinese Diesel Heater |
Choosing a van
- Budget: The cost of a van can vary significantly, ranging from a few thousand dollars to tens of thousands. It's important to set a budget beforehand and keep an eye out for deals.
- Condition: When buying a used van, consider factors such as mileage, age, tire condition, air conditioning, clearance, unusual noises, leaks, and brakes.
- Type of van: Decide between a short or long-wheelbase vehicle, and whether you prefer a low or high roof. If you plan to stand up in the van, a high roof is essential.
- Mechanical skills: If you're mechanically inclined, you may want an older van that requires occasional mechanical work. Otherwise, a newer van with fewer maintenance needs may be a better option.
- Number of travellers: The number of people travelling in the van will impact the amount of space needed. A larger group will require a bigger van with a longer wheelbase.
- Stealth camping: If you plan on stealth camping in urban areas, consider choosing a van that blends in with cargo vans rather than one that looks like a typical campervan.
- Standing height: If having the ability to stand fully upright in the van is important to you, look for vans with higher roofs, such as the Ford Transit.
- Bed type: Consider whether you prefer a fixed bed or a convertible bed/bench system. A fixed bed provides more storage space underneath, while a convertible bed saves space and can double as a seating area.
- Layout: Think about how you want to utilise the space in your van. Will you need a dedicated workspace? Do you require a toilet or shower? How much storage space is necessary? These factors will influence the layout and design of your campervan.
- Windows and ventilation: Consider the number and placement of windows, as well as the need for additional ventilation options such as roof vents or fans.
- Electrical system: Determine whether you will require a complex electrical system with solar panels and batteries, or if a simpler setup with a car inverter and tap lights will suffice.
- Water system: Decide if you need a built-in water system or if you can manage with a simpler solution, such as using public bathrooms and refilling water containers.
- Heating: Evaluate the need for a heating system, especially if you plan to travel in colder climates. Options include propane heaters or gasoline-powered heaters.
- Personal preferences: Ultimately, choose a van that aligns with your personal preferences and lifestyle. Consider the features that are most important to you and use them as a guide in your decision-making process.
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Design a layout
Designing a layout for your camper van is an exciting part of the conversion process. It is important to consider your unique needs and preferences when deciding on a layout. Here are some key factors to keep in mind:
Bed Style
The bed area typically takes up the most space in a camper van. You can choose between a fixed platform bed, which offers storage space underneath, or a convertible bed/bench system that provides more lounge space. If you are working with limited space, a convertible bed or a Murphy bed that can be stowed away when not in use might be a better option.
Kitchen Setup
Decide whether you want an indoor or outdoor kitchen. Consider the amount of counter space and storage you need, as well as what appliances you plan to include, such as a refrigerator, stove, or sink.
Storage Solutions
Think about the type of gear you will need to store, such as adventure equipment, clothing, and food supplies. Utilise space under the bed, overhead cabinets, and custom-built storage compartments to maximise storage capacity.
Electrical System
Determine your power needs and decide whether you will require solar panels, batteries, or a car inverter to run electronics and lighting.
Ventilation and Temperature Control
Consider installing a roof vent, window rosters, or a full shower/wet bath area for ventilation and temperature control. If you plan to travel in colder climates, insulation may be necessary to retain heat.
Seating and Lounge Area
If you don't have a bed that converts into a seating area, allocate space for benches or swivel seats. This will ensure comfort and functionality during your travels.
Bathroom Facilities
Decide whether you want a built-in bathroom or a more compact solution, such as a pop-up shower or portable toilet.
Work Space
If you plan to work remotely, create a dedicated workspace with a table and adequate ergonomics.
Aesthetics and Comfort
Add personal touches to make your camper van feel like home. This can include curtains, cushions, lighting, and decorative accessories.
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Install windows and ventilation
Windows and ventilation are crucial to your campervan. They let in natural light, provide a view of the outside world, and ensure proper airflow to keep the interior comfortable. Here are the steps to install windows and ventilation in your homemade camper van:
Step 1: Plan the Window and Ventilation Layout
Before cutting any holes in your van, carefully plan the placement of windows and ventilation fans. Consider factors such as privacy, airflow, and natural light when deciding on the number and location of windows. Mark the planned locations with masking tape to visualise the layout. Remember to place ventilation fans near the shower to prevent mould and mildew.
Step 2: Cut Holes for Windows and Ventilation
This step involves cutting holes in your van's exterior, which can be intimidating. Measure twice and cut once to ensure accurate placement. Use the appropriate tools to cut through the metal and create holes for windows and ventilation fans. Remember to clean up metal shavings afterwards to prevent rusting.
Step 3: Install Windows
Install the windows by fitting them into the cut-out holes and sealing them securely. Ensure the windows are weatherproof and firmly attached to prevent leaks and draughts.
Step 4: Install Ventilation Fans
Install roof vent fans, typically placed over the sleeping area and kitchen area to ensure adequate airflow. Follow the manufacturer's instructions for proper installation. You may also want to consider installing window rosters for additional ventilation and rain protection.
Step 5: Test and Seal
Once the windows and ventilation fans are installed, test their functionality and ensure there are no leaks or gaps. If necessary, use UV-resistant sealant or kit to close any small gaps or leaks around the installations.
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Insulation
Materials
- Insulation boards, such as Kingspan or Celotex, are commonly used for larger camper van conversions, especially for under floorboards. These boards have a silver foil casing to reflect heat back into the living space and can be easily cut to fit any shape.
- Aluminium tape to cover joins and gaps, maximising the area reflecting heat.
- Loft insulation or glass mineral wool, also known as Eko Roll or Eco Roll, can be torn into strips and pushed into small spaces in the van.
- ThermaWrap, a general-purpose insulation similar to bubble wrap lined with silver foil on both sides, can be attached to the walls using spray adhesive and aluminium tape.
- Softwood beams, such as softwood pine, the same width as the van ribs, to create a rib cage that holds the insulation and cladding/plywood in place.
- Cladding or plywood boards for attaching to the rib cage.
- Sound deadening material to reduce noise while driving, especially on the metal floor of the cab area and the ribbed floor of the van.
- Expanding foam to fill in gaps and seal off areas.
- Spray adhesive for attaching ThermaWrap to the walls.
- Gloves and masks for safety when working with insulation materials.
Process
- Plan and clean: Before starting, it is important to plan the electrical system and make any window or roof cut-outs. Clean the van thoroughly and check for any areas that need attention, such as cracks or rust, and address them before insulating.
- Install sound deadening: Apply a sound deadener like Killmat or Noico to the sheet metal of the van to reduce vibration and noise. Covering 25% of each panel, including the floor and wheel wells, is usually sufficient.
- Install floor insulation: Start by creating a grid pattern with wooden furring strips attached to the floor using marine sealant. Cut insulation boards to fit between the strips and tape them in place with foil tape. Then, screw the subfloor into the furring strips.
- Install ThermaWrap: Attach ThermaWrap to the walls of the van using spray adhesive and cover any gaps with aluminium tape. This step is optional and only necessary if using insulation other than Kingspan or Celotex.
- Install the rib cage: Measure the height of the van and the width of the metal ribs. Drill pilot holes in the wood, push it against the metal ribs, and attach with screws.
- Install cladding and insulation: Place cladding or plywood boards against the rib cage at the bottom of the wall and drill holes to attach them. Fill the gap between the cladding and ThermaWrap with glass mineral wool or insulation boards, trimming any excess with a craft knife.
- Finish with expanding foam: Use expanding foam sparingly to fill any remaining gaps or exposed edges. Ensure not to block any cable conduit areas.
Tips
- Prioritise effective insulation materials to keep the van warm and comfortable.
- Consider the R-value (resistance to heat flow) of different materials, especially in relation to space and cost constraints.
- Address all three types of heat transfer (radiation, conduction, and convection) for optimal insulation.
- Proper ventilation is key to reducing condensation and preventing mould.
- Seal off as much moisture from the outside as possible, but be aware that creating a perfect moisture barrier is challenging in a vehicle.
- Insulate the ceiling and walls with rigid foam panels or spray foam for thicker insulation to mitigate convective heat loss.
- Insulate windows with reflective surfaces, such as Infrastop or Reflectix, to keep the van cooler in warm weather and warmer in cold weather.
- Consider eco-friendly insulation options like sheep's wool or cork, which provide good thermal protection but may be more expensive.
- Remember that every ounce counts when living in a van, so consider the weight of the insulation and its impact on gas mileage and vehicle handling.
- Ensure proper installation and sealing to prevent heat escape and cold air seepage.
- If you're unsure about the installation process, consider hiring a professional to ensure a high-quality result.
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Electricity
The electrical system is one of the most important parts of your campervan conversion. It will power your appliances, lights, and devices, and will make your van self-sufficient. Here are the steps to installing electricity in your campervan:
Determine Your Power Needs
Before setting up your electrical system, you need to figure out how much power you will be using. Consider what appliances you will be powering, such as a fridge, how many lights you want, and how many devices you will be charging. This will help you determine the size and number of batteries you need, as well as the number of solar panels.
Choose Your Electrical Components
After figuring out your power needs, it's time to purchase the necessary components for your electrical system. This includes batteries, a solar charge controller, an inverter, and wiring. You may also want to consider a battery isolation switch, which allows you to disconnect the battery from the electrical system if needed.
Install the Electrical System
Now it's time to wire everything together. This step is best left to a professional electrician to ensure your system is installed safely and correctly. They will connect your batteries, solar panels, and inverter, and run the wiring to your appliances and devices.
Test and Maintain Your System
Once your electrical system is installed, test it to ensure everything is functioning properly. Regular maintenance is also important to keep your system in good condition. This includes checking your battery water levels, cleaning your solar panels, and tightening any loose connections.
Consider a Backup Power Source
It's always a good idea to have a backup power source in case your primary system fails or you need extra power. This could be a portable power station, a generator, or simply plugging into shore power at a campsite.
Practice Electrical Safety
When working with electricity, safety is paramount. Always follow proper safety procedures, such as turning off the power before working on the system, using the correct wire gauges, and avoiding overloading your system. It's also a good idea to have a fire extinguisher and a carbon monoxide detector in your van.
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Frequently asked questions
The cost of converting a van into a campervan depends on your budget and preferences. A basic conversion can be done for a few thousand dollars, but if you want to add more features such as solar panels, a fridge, or a built-in bathroom, the cost can quickly increase to $10,000 or more. It's important to plan and research the costs of the individual components before starting the conversion process.
The best type of van for a campervan conversion depends on your needs and budget. Some popular options include the Mercedes Sprinter, Ford Transit, and Ram ProMaster due to their reliability, size, and maneuverability. However, if you're on a tight budget, consider older models such as the Ford Econoline, Chevy Astro Van, or Dodge Ram Van.
The essential steps in converting a van into a campervan include stripping and cleaning the van, insulation, building the framework and furniture, installing electrical and plumbing systems, and adding final touches such as curtains and storage solutions. It's important to plan the layout and design carefully before beginning the conversion process.
Some common mistakes to avoid when converting a van into a campervan include not planning the layout carefully, not considering weight distribution, and not allowing for proper ventilation. It's also important to ensure that all electrical and plumbing connections are secure and safe to avoid any potential hazards.