The Ultimate Guide To Building Your Own Camper

Building your own camper is a challenging but rewarding project. It requires a range of skills, from design and construction to electrical and plumbing work. The first step is to plan the design, gather materials and create a solid base. The next steps involve building and insulating the walls, shaping and hanging the roof, and finishing the interior. The electrical system is a key component, and it's important to choose high-quality, durable materials that can withstand the rigours of camping. Finally, adding personal touches, such as a pull-out bed or custom door, can make your camper unique.

Planning and design

The next step is to decide on the type of van or truck you will convert. This could be a full-size pickup, midsize truck, or small pickup. You should also consider whether you prefer a short or long-wheelbase vehicle, and if you want a low or high roof.

Once you have decided on the type of vehicle, it is time to start designing the layout. Consider how many people will be using the camper and how much space you will need for seating and sleeping. Think about the type of bed you would like and whether you need a convertible bed to save space. You should also decide if you want to include a bathroom and/or kitchen area.

When designing the layout, it is important to consider the weight distribution and ensure that heavy items are kept near the center line of the van or truck. You should also think about the materials you will use, opting for lightweight yet durable options such as aluminum or wood.

Before beginning construction, it is crucial to gather all the necessary materials and tools. This includes plywood for the frame, insulation materials, screws, sealant, and any other specific items required for your design.

Finally, consider adding personal touches to make the space your own, such as choosing colors and materials that create a cozy and inviting atmosphere.

Building the walls and roof

Planning and Materials

Before you begin construction, it's essential to have a clear plan and gather the necessary materials. Measure the dimensions of your van and sketch out the layout of your walls and roof. Determine the placement of windows, doors, and any other features. Decide on the type of framing and materials you'll be using—commonly used options include plywood, tongue and groove panels, or 1x4s/1x6s for a lightweight frame. Create a list of required tools and materials, such as lumber, screws, adhesive, insulation, and backing material.

Framing and Structure

The first step is to build the framework for your walls and roof. This involves creating a sturdy structure that will support the weight of your van's interior elements and maximise space efficiency.

• Framing Techniques: When creating the frame, avoid the traditional 16-inch spacing. Instead, tailor the frame to your furniture layout. Place vertical studs behind cabinets or heavy items and horizontal studs along walls where countertops will be installed. In areas without furniture, you can reduce the number of studs or eliminate them, using lightweight wall panels or insulation instead.
• Securing the Frame: Use high-quality treated lumber, such as 1x4s or 1x6s, for your studs. Secure them to the van's metal frame or existing wall studs using self-drilling metal screws with a silicone coating to prevent rust. You can also use construction adhesive along with screws for added strength. Ensure that your frame is level and plumb.
• Creating Inset Walls: To optimise space, you can create "inset walls" around windows and your bed platform. These insets recess slightly from the main wall, providing extra headroom and storage space. Build the inset frame using 1x4s or 1x6s, depending on your desired depth. Secure the frame to the van's wall or existing studs. You can also add insulation within the inset cavity for better temperature regulation.

Wall Panels and Finishing

Once your frame is in place, it's time to attach the wall panels and finish the surfaces.

• Choosing Wall Panels: You have several options for wall panels, including plywood, tongue and groove panels, or lightweight alternatives. Plywood is a versatile option that can be painted, stained, or upholstered. Tongue and groove panels create a clean, seamless look and are typically made from materials like cedar.
• Attaching Wall Panels: When attaching wall panels, it's best to use furring strips along the length of the van to minimise the number of screws going directly into the metal. Cut your panels to size, working in sections to minimise seams. Secure the panels to the furring strips with screws. For curved areas, you may need to scribe the panels or use a Dremel tool for detailed cuts.
• Finishing Touches: You can finish your walls with paint, stain, or fabric. Painting or staining is a typical home-style finish, while upholstering with fabric adds a cosy touch. If you choose fabric, consider adding a thin layer of closed-cell foam underneath for a softer feel.

Roof Construction

The roof of your camper van is equally important and requires careful construction.

• Framing the Roof: The roof frame should be sturdy enough to support the weight of any additional features, such as solar panels or air conditioning units. Use treated lumber and secure it directly to the van's metal frame or existing roof ribs. Ensure the frame is level and sturdy.
• Insulating the Roof: Proper insulation is crucial for maintaining a comfortable temperature in your van. Use suitable insulation materials, such as foam boards, and cover them with insulation foil. Ensure that any openings or vents are properly sealed.
• Roofing Materials: For the outer roof surface, consider using lightweight and durable materials like aluminium or fibreglass. These materials are easy to work with and provide a weather-resistant barrier. You can also add a roof rack for additional storage or mount solar panels for off-grid power.

Installing doors and windows

Planning and Preparation:

• Decide on the type and number of windows you want: Consider factors such as ventilation, view, privacy, and cost. You may choose between bonded van windows, framed acrylic windows, or other custom options. Determine the placement of each window, keeping in mind any furniture or interior layout constraints.
• Gather the necessary tools and materials: You will need a jigsaw, drill, safety gear (goggles, gloves, dust mask), measuring tape, plywood or other door/window materials, hinges, screws, door handle, weather stripping, insulation, and adhesive or glue suitable for your window type.
• Measure and cut the door or window openings: Measure the dimensions of the door frame or window openings, and cut the plywood or other material to size. Smooth the edges with sandpaper if necessary.

Installation Process:

• Install insulation (for doors): Attach insulation to the inside of the door to regulate the temperature in your camper.
• Attach hinges (for doors): Screw hinges onto the door, ensuring they are evenly spaced and aligned.
• Add weather stripping (for doors): Apply weather stripping around the edges of the door to prevent drafts and moisture.
• Install the door handle (for doors): Securely attach the door handle, ensuring it is easy to grip.
• Prepare the window openings: Make a template for the window cutout by tracing the window frame on a piece of cardboard or plywood. Tape the template to the outside of the van, aligning it with the desired position for the window. Drill holes along the template to guide your jigsaw cut.
• Cut the window openings: Drill holes large enough for the jigsaw blade to fit, and cut along the marked lines. Use masking tape or cardboard to protect the surrounding paintwork from sparks and metal filings.
• File and treat the edges: Use a metal file to smooth any rough edges, and apply rust-proof paint to prevent corrosion.
• Apply primer and adhesive: Follow the instructions provided with your windows. Apply primer to the window edges and adhesive to the van and window surfaces. Ensure the primer has enough time to dry before attaching the window.
• Install the windows: Carefully lift and press the window into place, ensuring it is positioned correctly. You may need an extra pair of hands for larger windows. Secure the window with tape to hold it in place while the adhesive dries.
• Attach the window trim: Once the adhesive is fully set, cover the sharp interior edges of the window with trim for a finished look and added safety.

Remember to work with patience and precision, especially when cutting holes in your van and applying adhesives. Always wear the appropriate safety gear and work in a well-ventilated area.

Electrical wiring and plumbing

Planning and Materials

Before you begin, it is important to plan your electrical system carefully and consult an expert if you are unsure. You will need to determine the wire sizes, fuse sizes, and other parts needed for your system. Use a wiring diagram as a reference and make sure to follow regulatory guidelines for wiring installations (BS 7671 in the UK and NEC in the USA).

Wires and Cables

Use multi-stranded wires as they are easier to route and better able to handle vibrations. The thickness of the wire is determined by the amount of amps passing through it and the distance from the battery. AWG (American Wire Gauge) is the standard measurement for wire diameter, with smaller gauges indicating larger diameters.

Fuses

Fuses protect the wiring by preventing overloading. Install fuses that are appropriately sized for your wires, with the fuse size determined by the current rating of the wire. Place the fuse as close to the battery as possible, and ensure all circuits that can have power running through them are fused.

Fuse Blocks and Bus Bars

Fuse blocks and bus bars help to organise power distribution from your batteries to your electronic accessories. A bus bar is a metal component that attaches to the return (-) wires, and many fuse blocks have built-in bus bars.

Grounding

Grounding your electrical system is important, but using the vehicle chassis as a ground is discouraged due to the risk of galvanic corrosion and feedback loops. Instead, run a pair of wires and ground your battery and any metal ground terminals on your electrical parts.

Planning Wire Routes

Keep your wires as short as possible, especially for high-current parts, to minimise efficiency loss. Place your batteries close to your charge controller and inverter. Consider using PVC pipes within the walls to easily add or troubleshoot wires in the future.

Terminals and Crimping

Use a crimper to attach terminals to wires, ensuring that the connector is appropriate for the wire size. When attaching cables to your battery, sandwiching washers between the connecting surfaces is not recommended as it increases electrical resistance.

Solar Panels

Connect solar panels to your system last, and always disconnect them first when making changes. Disconnect the negative battery terminal before working on electrical systems, and follow the recommended order of assembly and disassembly.

Tools and Safety

Invest in a digital multi-meter to help with electrical work and troubleshooting. Use dielectric grease on connections to prevent corrosion, and always prioritise safety when working with electrical systems.

Interior decoration

Decorating the interior of your camper can make it feel more like home. Here are some tips to help you get started:

Choose a Colour Scheme

If you have a vintage camper or a modern RV, you can give its interior a fresh look by choosing a colour scheme that makes the space feel clean, cosy, and inviting. Paint the walls, paint or replace the cabinets, cover cushions with fabric, and hang colour-coordinated curtains to give the interior a stylish upgrade.

Incorporate Pops of Colour

If you prefer to keep the interior of your camper white, you can still add some colour to liven up the space. Vibrant rugs, colourful throws, and patterned pillows are excellent, low-commitment ways to bring some colour into your camper.

Hang Up Some Wall Art

Just like at home, you can hang family pictures, inspiring quotes, posters, and beautiful paintings in your camper. It's a great way to express your personality and make the space feel more like yours.

Use Textiles to Create Warmth

Adding and layering textiles is an easy way to make your camper feel warmer and more inviting. Area rugs, for example, can add visual warmth and keep your toes cosy on chilly days. Throw blankets and decorative pillows are also great for adding colour, texture, and a homey touch to your camper.

Upgrade Your Bedding

Most RVs come with thin, basic, and uncomfortable mattresses. Upgrading your mattress or adding a mattress topper can make a big difference in your comfort and help you get a good night's sleep. You can also incorporate your favourite bedding from home, such as a down comforter, to make your bed feel more familiar and cosy.

Personalize with Sentimental Items

Incorporating sentimental items and personal touches is a great way to make your camper feel like home. Hang artwork and picture frames using Command Strips to avoid putting holes in the walls. Bring along a Bluetooth speaker or a record player to play your favourite tunes and add some visual appeal to your space. Plants and fresh flowers can also help to brighten up your camper and improve the air quality.

Frequently asked questions