Transforming Your Van Into A Cozy Mobile Camper

how to make camper out of a van

How to Make a Camper Out of a Van

Introduction

Turning a van into a camper is a rewarding project. It allows you to design and build a unique living space that suits your needs and preferences. However, one size does not fit all when it comes to van life. In this article, we will take you through the process of converting a van into a camper, covering everything from planning to execution. So, whether you're a first-time builder or a seasoned pro, read on for a step-by-step guide to creating your dream camper van.

Step 1: Planning and Design

Before you start the conversion process, it is essential to have a clear idea of what you want your camper to look like and how you plan to use it. Consider factors such as your budget, the type of van you will be using, the number of people who will be using the camper, and your personal preferences for features like beds, kitchens, and storage. Creating a detailed plan and design will make the build process much smoother.

Step 2: Gathering Materials and Tools

Once you have a clear idea of your design and layout, it's time to gather all the necessary materials and tools. This includes things like insulation, plywood, screws, windows, electrical components, plumbing fixtures, and any other specific items you may need for your build. It is also a good idea to have a basic set of tools, including power tools like a drill, jigsaw, and screwdriver, as well as measuring tools and safety gear.

Step 3: Cutting Holes and Initial Setup

The first step in the actual conversion process is to cut holes in the van for windows, vents, and other fixtures. This can be a daunting task, so take your time and be precise. After cutting the holes, you can start installing some of the initial components like windows, fans, and electrical inlet points.

Step 4: Insulation and Flooring

Insulating your van is crucial for maintaining a comfortable temperature. Common insulation materials include foam boards, Thinsulate, and recycled plastic loft insulation. Once the insulation is in place, you can move on to installing the subfloor and flooring. Plywood is a popular choice for subfloors, and vinyl flooring is a durable and affordable option for the final floor covering.

Step 5: Building the Framework and Furniture

Now it's time to build the framework and furniture for your camper. This includes constructing the bed, kitchen counters, cabinets, and any other custom features you have designed. It's important to measure and plan carefully to ensure everything fits perfectly. You may also need to install additional support beams or studs to provide a solid foundation for your furniture.

Step 6: Electrical and Plumbing Systems

Installing electrical and plumbing systems is a complex but essential part of the conversion process. For electrical systems, you'll need to consider power sources like solar panels or generators, battery setups, and wiring for lights, appliances, and outlets. For plumbing, you'll need to plan the water tank and pump system, as well as any sinks, showers, or toilets you plan to include. It is highly recommended to consult with professionals for these steps to ensure safe and proper installation.

Step 7: Finishing Touches and Decor

Finally, it's time to add the finishing touches that will make your camper feel like home. This includes things like curtains, storage solutions, decorative items, and any other personal touches that reflect your style. Don't be afraid to get creative and make your camper truly yours!

Conclusion

Converting a van into a camper is a challenging but rewarding project. It requires careful planning, a range of skills, and a dedication to seeing it through. However, with the right approach and attention to detail, anyone can create their dream camper van. So, get ready to hit the road and enjoy the freedom and adventure that van life has to offer!

Characteristics Values
Budget $2000-$20,000
Van Type Sprinter Vans, Ram Promaster, Ford Transit
Van Features High roof, ability to stand up, longer wheelbase, cargo van
Van Source Car dealership, Craigslist, Facebook groups
Layout Fixed bed, convertible bed, kitchen, bathroom, workspace, storage
Materials Plywood, 2x4s, 2x6s, screws, glue, expanding foam, foam boards, insulation foil, tongue and groove planks, vinyl flooring, curtains
Electricity Solar panels, battery isolation switch, solar charge controller, electrical system wiring
Water Water tank, filtration system, pump, hose, shower, sink
Gas LPG canister, copper pipes, gas engineer

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Choose a van

Choosing the right van is crucial when converting a van for camping, as you’ll want to be certain the van you choose well suits your needs for van life. Here are some things to consider when choosing a van:

  • Mechanical Work: If you’re mechanically inclined, you may want a sick older van like a T2 Volkswagon (Vanagon) that needs mechanical work from time to time. If not, then a newer van that needs less work may be better.
  • Height: Is the ability to fully stand up in your van conversion a priority? This is very important. Anyone wanting to be able to stand up in their campervan will want a van with a higher roof, like a Ford Transit.
  • Number of People: Most likely, someone traveling in the van solo will need less space than a couple or family. If you plan to share your camperized van with others, it’s best to purchase a larger van with a longer wheelbase.
  • Stealth Camping: Anyone who plans on stealth camping on city streets in their campervan will likely want a van that looks more like a cargo van than a van someone is living in, like a Nissan NV or Ram Promaster.

While the best van to buy to convert to a campervan varies for everyone, the top three seem to repeatedly include:

  • Sprinter Vans: Sprinter Vans are by far the most popular vans for converting a van to a camper van due to their reliability, size, diesel engine, and size and shape.
  • The Ram Promaster: The Ram Promaster is another one of the most popular vans for campervan conversion due to its width, maneuverability, and fuel efficiency.
  • The Ford Transit: The Ford Transit is also incredibly popular due to their affordability, and because they are one of the tallest vans on the market.

If you’re still wondering which van to build into a campervan conversion, it’s worth considering the following:

  • Your budget: The van will add an additional $2000-$80,000 to your total conversion cost.
  • Your needs: Consider how many people will be travelling in the van, whether you need to be able to stand up, and whether you plan on stealth camping.

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Design your layout

Designing the layout of your camper van is one of the most important steps in the conversion process. The layout will depend on your needs, preferences, and the type of van you have. Here are some steps and considerations to help you design your camper van layout:

Step 1: Determine Your Requirements

Before designing your layout, think about how you plan to use the space and who will be using it. Consider the following:

  • The type of van you will convert (short or long wheelbase, low or high roof)
  • The number of people who will use the camper and their needs (e.g., bed and seating arrangements)
  • The type of bed you prefer (fixed, convertible, or stowable)
  • Your daily routine and how you'll use the van (e.g., full-time living, occasional trips)
  • Your power and water system requirements
  • The amount of storage space you need
  • The additions to the roof (e.g., roof racks, solar panels, roof fans)
  • The climate and locations where you'll spend most of your time

Step 2: Create a List of Essentials

Make a list of everything you want and need in your van, including furniture, appliances, and other items. Prioritize the essentials to ensure they fit into your layout.

Step 3: Mix and Match Layout Options

Experiment with different layout options by mixing and matching various elements. Consider using a 3D design tool or graph paper to visualize the layout. Here are some common layout elements to consider:

  • Fixed platform bed with storage underneath
  • Convertible bed (dinettes, benches, couches)
  • Stowable beds (Murphy beds, lifting beds)
  • Seating options (bench seats, swivel seats)
  • Kitchen and cooking facilities (indoor or outdoor)
  • Bathroom and shower options (built-in, pop-up, portable)
  • Storage solutions (upper cabinets, under-bed storage, garage space)

Step 4: Create Mock-up Layouts

Create multiple mock-up layouts to see how your bed, seating, kitchen, and bathroom will fit in the van. You can use 3D design tools or graph paper to visualize the arrangements.

Step 5: Customize and Perfect Your Layout

Once you've chosen a layout that works for your needs, refine and customize it by adding details like furniture measurements, electrical outlets, windows, and other accessories. Use a first-person view in your 3D design tool to experience the layout virtually.

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Insulation

There are several types of insulation to choose from, and the best type for your van will depend on your budget, the van's size, and the local climate. Here is a step-by-step guide on insulating your van:

Step 1: Assess and Plan

First, determine the areas that need insulation. Usually, this will be the wall, ceiling, and floor. Consider the climate and the amount of insulation you will need.

Step 2: Clear and Clean the Van

Remove any unnecessary items, debris, or existing insulating materials. Clean the insulation surfaces from dust, moisture, dirt, and grease.

Step 3: Prepare the Insulation Area

The main focus for van insulation should be the cargo area. Demarcate the front seats from the cargo area, and cover and protect areas such as windows, doors, electrical components, and fixtures.

Step 4: Choose the Right Insulation

Use high-quality insulation products to guarantee effective van insulation. For example, Kraken Bond FastCoat Spray Foam has high adhesion, low expansion, and excellent thermal resistance.

Step 5: Gather Materials and Tools

You will need a foam gun, utility knife, gloves, goggles, and other protective clothing.

Step 6: Apply the Insulation

Start with the ceiling, then move to the walls, and lastly, the floor. Apply the foam evenly across the wall, ceiling, and floor of the van. Fill gaps, cracks, and cavities, paying close attention to corners, seams, and areas prone to heat loss or air leakage.

Step 7: Trim Excess Foam

As the foam expands, use a utility knife to trim off excess foam to create a smooth and even finish.

Step 8: Wait for the Foam to Cure

Allow the foam to dry and cure properly according to the manufacturer's instructions.

Step 9: Inspect and Seal Gaps

After the curing process, check for missed spots and apply foam as needed. Inspect and seal gaps properly.

Step 10: Finishing Touches

After insulating, add finishing touches to cover the foam, such as panelling or fixtures, to make your van conversion look neat.

Types of Insulation

Spray Foam Insulation

Spray foam is highly durable and usually requires hiring a professional for installation. It is the most expensive insulation option, costing between $1500 and $3000. It is also the best insulation for floors because it creates a thermal barrier to resist heat retention. Spray foam also has superior air-sealing abilities, waterproofing abilities, soundproofing qualities, and versatility. It is a wise investment, as it is highly durable and will last for many years.

Thermal Insulation Board

Thermal insulation boards, such as Celotex, Recticel, and Kingspan, have excellent thermal properties. A 40mm thermal insulation board has an R-value of 1.8, whereas polystyrene board has an R-value of 1.05. Cutting these boards to size is super easy; you can score them to mark out sizes and then chop them with a saw or bread knife.

Rolls of Wool Insulation

Recycled bottle wool is much nicer to work with than fibreglass or rock wool. It is not itchy, and you don't need to wear a mask. It is also much more eco-friendly as it is made from recycled bottles.

Vapour Barrier

A vapour barrier is important to prevent condensation from reaching the insulation. It is a heavily contested area, with some people saying it is impossible to fully seal and therefore not worth it. However, Charlie and Dale of Nohma, authors of The Van Conversion Bible, are convinced of its benefits. In their experience, vans without a vapour barrier get very damp overnight and develop mould issues.

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Install electrics

Now that you've built the framework and furniture of your campervan, it's time to install the electrical system. This is an incredibly important step as it makes your van self-sufficient.

Before setting up the electrical system in your campervan, you'll want to figure out how much power you will be using. For example, will you be powering a fridge or any other kitchen appliances? How many lights do you want in your van? How many electronics will you be charging?

After figuring out how much power you need in your campervan, it's time to purchase the necessary components of your campervan's electrical system!

  • Battery Isolation Switch
  • Solar Charge Controller

Installing the Electrical System

After buying all of the electrical system parts, it's time to wire it all together! For this process, it is worth hiring a professional electrician for safety reasons and to ensure your system runs properly without damaging any equipment.

Example Electrical System Setup

  • SOLAR: 2 x 160W | Victron MPPT
  • ALTERNATOR CHARGE: Victron Orion XS
  • SHORE POWER: 30A Samlex charger/converter
  • BATTERY BANK: BattleBorn Lithium 200Ah
  • MONITORING: Simarine Pico

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Install gas

Gas is a vital part of a campervan conversion, as it powers the kitchen, and heats the van. One of the most popular methods is to install a refillable LPG canister either underslung in the van, or in a sealed compartment inside the van itself. LPG is very cheap and easy to refill. To use the gas, it will need to be wired to your appliances with copper pipes.

Gas System Components

There are two sides of a campervan gas installation: a high-pressure side and a low-pressure side. The high-pressure side is everything before the regulator, including the filling point, gas bottle, and any hoses and connectors. The low-pressure side is everything after the regulator, including the copper piping and your appliances.

Gas Bottles

There are two types of campervan gas bottles: refillable and replaceable. Replaceable gas bottles are designed to be removed from the campervan gas installation and replaced when all the gas is used up. Refillable gas bottles, on the other hand, are permanent installations that are refuelled via a filling point in the side of the van.

Gas Regulations

According to the British Standards Institution, a gas installation should be done by a certified technician. A certified refillable campervan gas bottle must have the following:

  • An automatic refill cut-off at no more than 80% (as the gas expands when warm)
  • A manual shut-off valve
  • A pressure release valve
  • An overflow regulator
  • A shut-off valve on top of the cylinder when refuelling

Gas Types

When using a refillable campervan gas bottle, you can choose between propane, butane, "patio gas", and LPG. Butane is more efficient but doesn't work below 0°C, while propane does. Patio gas is the same as propane, but it takes a clip-on regulator, which is unsafe in a moving vehicle. LPG is a mixture of hydrocarbon gases and is non-toxic, non-corrosive, and has a high octane rating.

Gas Installation Safety

As mentioned, you should have a professional install your gas system. However, there are a few things you should do to increase the safety of your system, including installing a carbon monoxide detector and smoke alarm, and a gas leak detector near the floor, as gas is heavier than air. You should also test every joint in your campervan gas installation for leaks.

Frequently asked questions

The first steps to converting a van into a camper are deciding on a budget, choosing a van, and designing the layout.

Some things to consider when choosing a van are:

- Your budget

- Whether you can work on the van yourself

- Whether you need to be able to stand up in the van

- How many people will be travelling in the van

- Whether you will be stealth camping

Some things to consider when designing the layout are:

- Whether you will be working in the van

- How many people the van needs to sleep

- Whether you want a bathroom with a shower

- Your storage space needs

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