Refurbishing A Vw Camper: A Step-By-Step Guide

Refurbishing a VW Camper is a challenging but rewarding endeavour. Whether you're a seasoned mechanic or a novice enthusiast, taking on this project requires dedication, imagination, and a good amount of money. The first step is to assess your budget and source a camper van, either with a neat fit-out or a minimum-rust shell. From there, it's a deep dive into repairs, replacements, and customisations. You'll be stripping out the interior, cleaning, and making repairs to the body, chassis, suspension, steering, brakes, and trim.

The good news is that you're not alone in this journey. There are plenty of resources available, from books like Mark Paxton's How to Restore Volkswagen (Bay Window) Bus to online forums and communities dedicated to VW enthusiasts. With their help, you'll be able to navigate the complexities of restoration and create a camper van that's not just a vehicle but a lifestyle.

Removing rust

Rust is a common issue for VW campervans, and it's important to address it early on to prevent further damage and ensure the safety of your vehicle. Here are some detailed steps to help you remove rust from your VW camper:

Identify Rust-Prone Areas:

Start by inspecting common problem areas such as the wheel arches, bottom of doors, sills, footwells, the cab floor, and floor panels underneath the van. These areas are particularly vulnerable to rust due to constant exposure to water and road salts.

Assess the Severity of Rust:

Use a screwdriver to tap and chip away at the rust. This will help you determine if it's just surface rust or if it has eaten through the metal. Remove any large, flaky bits of paint and rust with the screwdriver.

Remove Loose Paint and Rust:

Use a wire brush drill attachment and small handheld wire brushes to remove loose paint and rust. Focus on areas around the rust spots, leaving the complete removal of rust to the rust treatment.

Apply a Rust Treatment:

Coat the affected areas with a rust converter, such as Aquasteel. This will help transform any remaining traces of rust into a non-rusting surface. Allow the treatment to dry for a couple of days, and make sure to apply it generously around metal seams where water often gets trapped.

Fill in Rust Holes (if present):

If there are holes left by the rust, you can fill them using metal epoxy putty. This industrial-strength polymer compound can be moulded into any shape to repair patches of steel or iron. Make sure to wear protective gear, including a mask, during this process.

Sand the Metal Epoxy Putty:

After the putty has dried and hardened, use a random orbital sander to smoothen the surface. Sand down any excess putty to ensure a seamless finish.

Prime and Paint:

Apply a primer to protect the metal from future rust. This step is optional if you plan to use a metal paint that already includes a primer. Choose a paint that provides a smooth finish and protects the metal from further rusting. Paint both the top and underside of the repaired areas.

Apply an Underbody Seal (optional):

If the bottom of your van is in poor condition, consider applying an underbody sealant. This provides heavy-duty protection against moisture, road debris, stones, and corrosion.

Remember, rust removal and treatment is an ongoing process. Regularly inspect your VW camper for signs of rust and treat affected areas promptly. Additionally, preventive measures, such as regular washing, underbody protection, and rust inhibitor sprays, can help minimize the occurrence of rust.

Repairing body and chassis

Repairing the body and chassis of a VW camper van is a complex process that requires a range of skills and tools. Here is a detailed guide to help you get started:

Assess the Damage and Create a Plan:

Before starting any repairs, it is crucial to thoroughly inspect the vehicle and assess the extent of the damage. Pay close attention to areas prone to rust, such as the rocker panels, battery tray, and structural components. Create a list of the repairs needed and gather the necessary tools and materials.

Strip Down and Clean:

Remove all interior components, including cupboards, vinyl flooring, carpeting, and underlay. Be vigilant in cleaning the entire van, including the annex and pop-top, to eliminate insects, spiders, and mould. This step is crucial for creating a safe and healthy working environment.

Repair Structural Damage:

If there is significant structural damage or rust, consider creating a rotisserie to facilitate repairs to the bottom of the van. Ensure the frame and torsion tubes are in good condition and not rusted through. Repair or replace the affected areas, prioritising safety and structural integrity.

Body Repairs:

For body repairs, you will need replacement panels and repair sections. Source high-quality VW Bay Bus repair panels, including cab doors, sliding doors, tailgates, wheel arches, and cab step repair sections. You may also need front-end conversion kits if you plan to change the late Bay front panel to an early Bay design.

Chassis Repairs:

For chassis repairs, you will need specific repair panels such as outriggers, crossmembers, jacking points, and chassis rail repair panels. Ensure you have all the necessary consumables, including degreaser, seam sealer, primer, and rust prevention products.

Refinishing:

Once the body and chassis repairs are complete, it's time to refinish the vehicle. This includes painting, trimming, and interior re-trimming. Consult a professional painter or auto body specialist to achieve a high-quality finish.

Remember, restoring a VW camper van is a challenging task that requires a range of skills and knowledge. If you are unsure about any aspect of the process, seek advice from experienced VW enthusiasts, online forums, or professionals in the field. Safety should always be your top priority.

Interior design

When refurbishing the interior of a VW camper, there are many things to consider. From the kitchen to the bedroom, the interior design of a VW camper can make or break the overall look and feel of the vehicle.

Kitchen

A great way to enhance the interior of your VW camper is to renovate the kitchen. This can be challenging due to the limited space, but it is important to see the pleasure in your cooking area. A fantastic motorhome kitchen is about storage, tasteful decoration, and making good use of the space. Consider adding tiles above the kitchen to give the sense of a separate room without taking up too much space. Colour-coordinate the tiles with the rest of your van to avoid any clashes, or opt for a simple white or light grey tile for a classic look. Save space by installing a counter that folds out or a portable stove for outdoor cooking. Hide your water tank under or above the counter to boost the aesthetic while keeping it easily accessible.

Bedroom

The bedroom is arguably what a campervan is all about—it's where you rest your head at night. Make sure the mattress is comfortable and suitable for longer trips. Memory foam is a great option for ultimate comfort. Test out the mattress before installing it, and consider keeping a set of sheets and a blanket dedicated to your van to avoid forgetting them. Combine your bed with extra storage by creating a DIY bed frame with storage space underneath. Alternatively, opt for a drop-down table bed or a flip bench bed design.

Storage

Optimising storage space is crucial in a VW camper to avoid a messy and crowded interior. Utilise hanging storage solutions, such as nets and hooks, to make the most of wall space. Use jam jars to store food items, fixing them to the bottom of a cabinet against the wall. Install additional shelves using spring-loaded hinges, or create a stowaway cutting board. Use smaller boxes or bins to prevent items from sliding around while driving, and consider using bungee cords or magnets to secure items in place.

Flooring

Don't neglect the floor of your VW camper. Opt for light-coloured wood to open up the space and consider adding a designated area for dirty shoes to reduce the spread of dirt. You can also add a rug to create a homely touch.

Accessories

Add mirrors to create the illusion of a larger space and to allow for easy checking of your appearance. Hide cables to maintain a tidy interior, and consider installing a built-in vase to encourage you to fill it with flowers. Solar panels can also be a great addition, providing sustainable energy for your travels and opening up more campsite options.

Seating

Create a portable seat that can be used both inside and outside the campervan. This provides additional seating options, especially during starry evenings.

Windows

Adding windows can bring more natural light into your VW camper, making rainy days more bearable and allowing you to catch some rays. Windows also open up the space and give you the option to add cute curtains.

Upholstery

Re-upholstering the interior of your VW camper can completely transform it. Source unique and beautiful fabrics from fabric markets, IKEA, or local fabric stores to make your motorhome truly one-of-a-kind.

Electrical Systems

Update the electrical systems in your VW camper to include modern conveniences. Install 240v hook-ups, leisure batteries, and split charging systems.

Paint

A fresh coat of paint can make a significant difference in the appearance of your VW camper. Use high-quality paint for durability and a long-lasting finish.

Vinyl

Give your camper a makeover with new vinyl. Consider using vinyl or non-woven wallpaper, which is firmer and more moisture-resistant.

Appliances

Install appliances such as a sink, cooker, grill, and fridge to enhance the functionality and comfort of your VW camper.

Bed Styles

Explore various bed styles, such as the Rock and Roll bed, to find the most suitable option for your needs.

Audio/Visual Systems

Upgrade the audio and visual systems in your VW camper to enhance your entertainment options during your travels.

Lighting

Update the lighting in your VW camper to create a cosy and well-lit space. Consider adding LED lighting or installing solar panels to power your lighting system.

Insulation

Add thermal and acoustic insulation to your VW camper to regulate temperature and reduce engine noise for a quieter and more comfortable driving experience.

Door Panels

Pay attention to your door panels and consider restoring or replacing them. You can also add new map pockets to enhance functionality and storage.

Headlining

Update the headlining of your VW camper to give it a fresh and modern look.

Electrical Issues

Address any electrical issues and consider rewiring your VW camper to ensure all systems are functioning safely and effectively.

Safety

Prioritise safety by installing features such as seat belts and crash-tested beds.

Personalisation

Remember that your VW camper should reflect your personal style and needs. Customise the interior to suit your specific requirements and preferences.

Professional Services

If you prefer a professional touch, seek out companies that specialise in VW camper interior design and refurbishment. They can help you create a bespoke interior that suits your needs and tastes.

Engine maintenance

The engine is the heart of your VW camper, and keeping it in good condition is essential for ensuring its longevity and performance. Here are some detailed instructions to help you refurbish and maintain your camper's engine:

Regular Servicing

Even if your VW camper has a good, mechanically sound engine, regular servicing will give it a fresh breath of life. Most of the basic maintenance you can do yourself. Change the oil and oil filter regularly, and check and replace the air filter as needed. Keep the engine clean by wiping down the exterior and using an air blower to remove any dust or debris.

Spark Plugs and Points

It is important to update spark plugs and points regularly. Refer to your VW camper's manual for the recommended replacement schedule. If you're unsure about the process, there are many online tutorials available that can guide you through spark plug and point replacement.

Fuses

Replace all fuses at regular intervals to avoid any electrical issues. Fuses are inexpensive and easy to replace, and it's a good idea to keep a few spares in your camper at all times.

Engine Overhaul

If your engine is experiencing major issues or has suffered significant damage, you may need to consider an overhaul. This involves removing the engine from the vehicle, disassembling it, and inspecting each component for wear or damage. Any damaged parts should be repaired or replaced. This is a complex process and may require the expertise of a professional mechanic.

Engine Bay Refurbishment

While not directly related to performance, refurbishing the engine bay can improve the overall appearance of your VW camper. Clean the engine bay thoroughly and consider repainting components to give them a fresh look. You can also add custom touches, such as polished metal parts or coloured engine covers, to make your engine bay stand out.

Tools and Resources

When working on your VW camper's engine, it's important to have the right tools and resources. Invest in a good set of mechanic's tools, including wrenches, sockets, and a torque wrench. Additionally, refer to repair manuals and online forums specifically for VW campers, as they can provide valuable information and guidance on engine maintenance and repairs.

Remember to always exercise caution when working on your engine, and if you're unsure about any procedure, don't hesitate to consult a professional mechanic.

Cleaning

Step 1: Strip Out the Inside

Start by stripping out everything you can pull out, unscrew or remove. Take out any cupboards you intend to get rid of, anything broken, falling off or filthy. Pull up old vinyl, carpet and underlay. If the underlay crumbles when you rub a gloved hand across it, it's time to throw it away.

Step 2: Get Rid of Insects and Spiders

Set off an insect bomb inside the van. Place the can in the middle of the van, lift the pop-top up, and let it empty its contents. You may be dismayed at what comes crawling out!

Step 3: Deep Clean the Camper Van

Now it's time to clean. Wipe all the trim down, vacuum every speck of dust, and disinfect all the knobs, benches, walls and equipment. Sugar soap, dishwashing detergent and vinegar are cheap and effective cleaning products.

Step 4: Wash the Annex and Pop-Top

Brush off any dirt, cobwebs and vegetation from the campers’ annex and pop-top, then gently scrub with white vinegar. This will need to be done 1-2 times a year to remove any mould. Make sure you do this on a dry day so the canvas can dry in the sun.

Step 5: Replace Old Cushions

Discard old, soiled cushions. Think of all the people who may have slept on them before you, and the skin cells and mites they may have left behind! If the cushions are in good condition and you’re happy to recycle them, give them a thorough cleaning, some time in the sun, and an airing.

Step 6: Make Window Blackouts

Purchase enough silver sunshades to use as window blackouts. Measure and cut out the exact shape of each of the windows, hemming the edges using a zigzag stitch with a stiff ribbon. These will block out heat in summer and retain warmth in winter.

Step 7: Make Curtains

Add your own personality by making new curtains. Curtain material has a white rubber backing to block out sun and prying eyes. It should cost approximately $10 a metre, depending on the quality. The cheaper the material, the less effective it is at blocking out light.

Frequently asked questions