
Converting a cargo trailer into a camper is a challenging but rewarding project. It requires a range of skills, from electrical and metalworking to woodworking and plumbing. The process can take anywhere from a month to a couple of years, depending on the complexity of the design and the time you can dedicate to it.
The first step is planning the layout of your cargo trailer conversion. This includes researching different options and designs, creating a wish list of features, and drafting a floor plan. Once you have a plan, you can start executing your vision by stripping down the cargo trailer, framing and insulating the walls, installing electrical and plumbing, and finishing the interior with cabinets, flooring, and appliances.
Converting a cargo trailer into a camper can cost between $7,000 and $15,000, making it a more affordable option than buying a traditional RV. It allows you to customise your living space and include only the features you need, whether that's a basic setup with a cot and a sink or a full conversion with a kitchen, bathroom, and entertainment system.
With careful planning and execution, you can turn a cargo trailer into a comfortable and functional living space for your outdoor adventures.
Characteristics | Values |
---|---|
Cost | $7,000 - $15,000 |
Time | 1 month - 2 years |
Difficulty | Requires some DIY skills |
Weight | 2,500 - 7,200 lbs |
Length | 10 - 28 ft |
Width | 6 - 8 ft |
Height | 7 - 10 ft |
Power | Solar panels, shore power, generators |
Amenities | Kitchen, bathroom, beds, storage, HVAC, plumbing, electrical |
What You'll Learn
Electricals and plumbing
Electricals
The electrical system in your camper trailer will depend on how you plan to use it. If you will be spending a lot of time on campsites with access to electric hook-ups, you can install a shore power point on the side of your camper trailer. If you plan to spend most of your time off-grid, you can consider solar panels and a voltage sensing relay (VSR) or battery to battery (B2B) charger.
You can calculate the size of your electrical system by making a list of all the appliances you plan to use in your trailer and calculating the amp hours for each appliance. The formula for this is:
> Wattage / voltage = amp hours (Ah)
Where the voltage is 12V (the voltage of your batteries), and the wattage is the wattage of each appliance.
You should then calculate the total amp hours used by each appliance per day (Ah/day) by multiplying the amp hours by the hours the product will be used for per day. Add all of these together to get your total estimate Amp hour usage per day.
Next, decide how many days you want to be able to spend off-grid without charging. Most people aim for at least 3 full days. Multiply your total Amp hour usage per day by the number of days to get your required total usable capacity.
Different types of leisure batteries can be discharged by different amounts, so this will also affect the total battery capacity you will need. Sealed lead acid (SLA) leisure batteries are cheaper but can only be discharged up to 50% and have a shorter lifespan than Absorbent Glass Mat (AGM) or lithium-ion batteries.
Lithium-ion batteries are more expensive but can be discharged up to 90% and last longer. They are also smaller and lighter than AGM batteries.
Once you have decided on the type and size of your battery, you can calculate the total solar array you will need to effectively recharge your batteries. The formula for this is:
> Amp hours x voltage = watt hours (Wh)
Where voltage is 12V, the voltage of your batteries, and amp hours is the total usable capacity of your leisure batteries.
To calculate your solar array size, divide your watt hours by the total hours you would like to recharge in.
> Watt hours / hours to recharge = solar array wattage
There are around 8 hours of sunlight per day on average, so if you wanted to fully recharge your batteries in a day, the formula would be:
> 4512Wh / 8 hours = 564W solar array
However, it is unlikely that you will need to fully recharge your batteries in a single day, as you will likely have other methods of charging (e.g. shore power or a B2B charger).
To calculate the size of your solar charge controller, add together the voltage of your solar panels if they are wired in series, or the amperage if they are wired in parallel. Victron solar charge controllers have two main ratings: a maximum voltage and a maximum amperage. Each charge controller also has a maximum PV array size in watts.
When choosing a B2B charger, consider the voltage of your system and starter battery, how quickly you want to recharge your leisure batteries, and whether you need an isolated or non-isolated charger.
The formula for calculating recharge time is:
> Usable capacity of your battery (Ah) / current rating of the B2B (A) = hours to recharge
For example, 100Ah usable capacity / 50A B2B = 2 hours to fully recharge
Finally, you can calculate the size of your cables, fuses and busbars. Busbars and cables should be calculated based on the maximum current of your system, and fuses should be sized according to individual appliances and components. Cable gauge can be calculated based on the current rating of each component and the total length of the cable.
Plumbing
The plumbing system in your camper trailer will depend on how much water you need and whether you want hot water.
To calculate your water capacity, estimate how much water you think you will be using per day for cooking, drinking, washing pots, and washing yourself. Multiply this by how many days you would like to go between fill-ups to get your fresh water tank capacity.
As a comparison, two adults living full-time in a van use between 15-20L of water per day, so their 100L fresh water tank lasts them 5-7 days.
You will also need a waste or "grey" water tank. Most people halve the capacity of their fresh water tank to get the size of their grey water tank.
If you want hot water, you can install a water heater. Truma Ultrastore 10L Water Heaters can be connected to gas or 230V electricity, or both if you want the option to switch between the two power sources.
To supply water to your camper trailer, you have several options:
- Gravity-fed water system: Place your water container at a higher point than your sink or water bottle.
- Hand pump: Requires a pump faucet and some flexible tubing. Pressure from the pumping mechanism draws water up the tube and out of the faucet.
- Foot pump: Similar setup to the hand pump but allows for more control over the water flow and hands-free operation.
- 12-volt electric sink: Provides a consistent supply of running water and can be hooked up to a hot water heater.
In this guide, we have outlined the steps for installing electricals and plumbing in a camper trailer. By following these steps and calculating the correct sizes for your components, you can create a functional and comfortable living space in your camper trailer.
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Insulation and windows
Insulation is a critical aspect of your cargo trailer conversion, as it will enable you to regulate the temperature inside your camper. Without insulation, the interior of your trailer will be susceptible to heat transfer, making it uncomfortable in extreme weather conditions.
Types of Insulation
There are several types of insulation to consider for your cargo trailer conversion:
- Rigid Board: Rigid board insulation is commonly used in cargo trailer conversions due to its affordability and ease of installation. The two types of rigid board insulation are XPS (Extruded Polystyrene) and Polyisocyanurate (Polyiso). XPS is widely available at hardware stores and offers a good R-value per inch, making it an effective insulator. Polyiso, on the other hand, has a slightly better R-value and is more environmentally friendly, but it may be more expensive and less readily available.
- Spray Foam: Spray foam insulation is a popular choice for cargo trailer conversions due to its high R-value, ability to create a tight seal, and resistance to moisture damage. However, it can be messy and tricky to apply, and it may distort metal walls if not applied correctly. It is recommended to have spray foam insulation professionally installed.
- Rockwool: Rockwool is a mineral wool insulation made from basalt rock and recycled Slag. It is resistant to water, rot, mould, and mildew, and it effectively fills wall cavities to eliminate gaps and improve sound dampening. However, it is important to wear protective clothing when working with Rockwool as it can be itchy, and inhaling it can be harmful to your lungs.
- Other Types: Other types of insulation, such as fiberglass insulation and reflective insulation, are also available, but they may not be ideal for cargo trailer conversions due to moisture absorption, health hazards, and low R-values.
Steps for Insulating Your Cargo Trailer
- Insulate Walls, Ceiling, and Floor: Using foam board insulation, cover the walls, ceiling, and floor of your trailer. For the walls, you can use either XPS or Polyiso, depending on your preference and availability. For the ceiling, you may need to use a thinner and more flexible insulation, such as foil-backed EPS, to accommodate any curvature.
- Fill Gaps with Spray Foam: Use spray foam insulation to fill any gaps or cracks in the rigid foam boards. This will help create an airtight seal and prevent moisture from getting behind the insulation.
- Create a Thermal Break: Cover all exposed aluminium ribs and frame with a thermal break material, such as 1/4" XPS insulation or fanfold sheathing insulation. This will reduce thermal bridging and improve the overall effectiveness of your insulation.
- Seal Seams with Tape: Use HVAC tape or aluminium tape to seal all seams and create a moisture barrier. This will help prevent condensation and moisture buildup.
- Install Furring Strips: Attach wooden furring strips to the ribs or frame to create a solid base for attaching your interior walls and channels for electrical wiring.
Windows
Windows play a crucial role in the insulation of your cargo trailer conversion. Single-pane windows are common in campers and trailers, but they are not effective at keeping the cold out or the heat in. Here are some ways to improve the insulation of your windows:
- Use Clear Plastic Film: Apply clear plastic film to create a faux windowpane. This film creates a sealed air pocket that resists thermal exchange better than a single pane of glass.
- Upgrade to Multi-Pane Windows: Consider investing in multi-pane windows, which have two or more panes of glass with a pocket of argon gas in between. These windows provide an effective barrier against thermal exchange and will help keep your trailer warm during cold nights.
- Improve Window Dressings: Use insulated or solar curtains to block out the sun's radiant energy and improve the insulation of your windows. You can also attach the curtains to the walls with Velcro for a tighter seal.
- Check Caulking and Weather Stripping: Ensure the caulking around your windows is intact and replace any damaged weather stripping to prevent air leaks.
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Flooring and walls
Planning your campervan floor
It is important to plan the layout of your van before you start installing the floor. You should map out your entire floor plan ahead of time and decide where larger, more fixed objects will go, like your bed and kitchen galley. You should also think about the location and routes of your power and plumbing systems.
Materials for the campervan flooring
Your campervan flooring will consist of four layers, each serving a specific purpose:
- Sound-dampening material: This layer reduces road noise in the van and provides extra insulation.
- Insulation: This layer adds comfort by maintaining a comfortable temperature inside the van and preventing extreme weather from penetrating the interior.
- Subfloor: This layer provides strength and durability to the floor and is usually made of wood. It is the strongest part of the floor and can support heavy objects.
- Top layer: This is the visible layer of flooring that you walk on and should be watertight to protect the subfloor from spills. Common materials for the top layer include vinyl, laminate, and cork.
Important considerations for campervan flooring
- Compressive strength of insulation: Choose an insulation material with good compressive strength to prevent it from being compressed by heavy objects and losing its insulating properties.
- Durability: The durability of your flooring depends on the type of insulation and subfloor you use. Choose materials with sufficient strength to support the weight of your furniture and other objects.
- Height of the floor: Consider the vertical space available in your van when adding insulation and sound-dampening materials.
- Abrasion resistance: Choose flooring materials that are abrasion-resistant to reduce scratches and add a rug or floor mat to high-traffic areas.
Installation tips for campervan flooring
Keep these tips in mind during the installation process:
- Planning: Take the time to plan your installation thoroughly to avoid mistakes and extra costs later on.
- Teamwork: Determine if you need help and who is available to assist you.
- Environment: Consider the temperature and weather conditions when working indoors or outdoors, as they can affect the epoxy or adhesive used in the installation.
- Tools: Gather all the necessary tools in advance, including those needed for cutting and adhering materials.
- Patience: Don't rush the installation process to avoid costly mistakes.
- Cure times: Follow the cure times specified for epoxy products to avoid permanent waves in your campervan floor.
- Safety: Wear safety equipment such as safety glasses, gloves, and a mask or breathing apparatus during the installation.
Maintenance and repairs for campervan flooring
To maintain your campervan flooring and avoid costly repairs:
- Protection: Consider adding custom floor mats or taking off your shoes before entering the van to keep the floor clean and free from scratches.
- Regular cleaning: Sweep or mop the floor regularly to remove dirt and debris.
Walls
When it comes to the walls of your camper, there are a few key steps to follow:
- Framing and insulation: Use 2x4s to frame the walls and then insulate between the studs with your chosen insulation material.
- Electrical and plumbing: Run electrical wiring to the locations of outlets and lighting, and rough-in all your plumbing connections to ensure they fit before gluing them together.
- Finishing the walls: Seal the walls with 5mm plyboard or similar material, cutting out spaces for lighting and outlets. Prime or texture the walls as desired before painting.
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Solar panels and power
Solar panels are a great way to provide a reliable, clean, and cost-effective energy source for your cargo trailer camper. Here are some essential steps and considerations for installing and maintaining solar panels for your off-grid power needs:
Choosing the Right Solar Components:
- Power Output: Select solar panels based on your trailer's power demands. Panels rated between 100-400 watts are generally recommended.
- Type: Flexible solar panels are lightweight and ideal for curved surfaces, making them easier to install. Rigid glass-laminated panels are more durable and suitable for flat surfaces.
Installation Process:
- Mounting Brackets: Choose brackets based on your trailer roof material and panel type to ensure stable mounting. Securely fix the mounting brackets to the trailer roof, angled towards the sun. Seal the bracket holes with weather-resistant sealant.
- Connecting Panels: Attach solar panels to the brackets using screws and connect them to cables with MC4 connectors.
- Controller and Battery Setup: Connect the solar panels to the input of a solar charge controller and connect a battery to its output. An MPPT controller is recommended for improved efficiency.
- Wire Management: Use zip ties to secure and organise cables, keeping them away from sharp objects and movable parts. For outdoor exposure, reinforce cables with waterproof tape.
- Testing: After installation, test the system by checking the battery charging, solar power output, and device connectivity. Most controllers have indicators to monitor charging status.
Usage and Maintenance Tips:
- Cleaning: Regularly clean the solar panels to keep them free from dust, leaves, and debris for optimal performance.
- Cable Inspection: Periodically check cables and connectors for any damage or looseness to ensure a secure connection.
- Battery Monitoring: Keep an eye on battery charge levels to avoid overcharging or deep discharges, helping to extend battery life.
Determining the Number of Solar Panels:
- Calculate Daily Power Consumption: List all electrical devices and their wattage, then estimate daily usage in watt-hours (Wh).
- Determine Required Solar Output: Increase your daily power requirement by about 30% to account for efficiency losses and weather conditions.
- Choose Panel Specifications: Consider the power output of each panel and how many you'll need. For example, a 100W panel can generate around 400Wh per day in sunny weather.
- Weather and Backup: Consider adding extra panels to ensure consistent power in poor weather conditions.
- Battery System: Choose a battery system that can store power for nighttime or cloudy periods. A 12V 100Ah battery can store up to 1200Wh of power.
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Beds and storage
The bed and storage setup will depend on the size of your trailer and how many people you need to accommodate. If you're building bunks, consider using plywood to create the frames. You can also add fold-down beds to save space when they're not in use. For mattresses, memory foam is a good option, and you can find affordable options at many retailers.
If you're building beds that can be folded up and stored, consider using ropes to create a cot. This will provide more cushion than plywood, and you can route grooves for the rope so that the cot sits flush against the wall when folded down. You can also notch the legs so they fold flush when the cot is not in use.
For storage, consider using the L-track in the floor of your trailer. This will allow you to roll back the carpet and access floor anchors for securing items. You can also use the L-track to attach a bike rack or other gear mounts.
If you're building cabinets, make sure to anchor them to the studs to prevent shifting during transit. Install cabinet clasps to keep the doors shut while driving.
For a more industrial look, you can use 2x4s to frame the walls and then insulate between the studs. This will provide a sturdy base for your storage and sleeping areas.
When planning your layout, consider weight distribution and the placement of plumbing, ductwork, and electrical components. You may want to use masking tape and cardboard cutouts to visualise your design before you start cutting and building.
Finally, don't forget to add some personal touches to make your space feel like home. You can add decorations, lighting, and RV accessories to make your camper comfortable and functional.
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Frequently asked questions
A cargo trailer is a more customizable, cost-effective, and lightweight alternative to traditional RVs. It's also a great option if you can't find an RV that meets all your needs and wishlist items.
Converting a cargo trailer into a camper can cost anywhere from $7,000 to $15,000, depending on the features and amenities included. This is still a more affordable option compared to buying a traditional RV.
It's important to take your time when planning the layout to ensure you make the best use of your limited space. Consider your must-have features, create a wish list, and draft multiple floor plans to find the most suitable option. Get feedback from those who will be sharing the space with you to identify any potential problems.