DIY Guide to Converting a Van into a Fully Functioning Camper Van

Preparing for a DIY Camper Van Build

Converting a cargo van into a fully functional camper van can be an exciting and rewarding project. With some determination and DIY skills, you can create a customized living space on wheels tailored to your needs. While van builds require significant planning and labor, the freedom of the open road and ability to wake up in a new location every morning make the effort worthwhile.

If you're considering taking on your own camper van conversion, the first step is finding the right van. Choose a van with enough interior space to accommodate your intended layout and sufficient payload capacity to handle the additional weight of the build. Popular choices include the Ford Transit, Mercedes Sprinter, and Ram ProMaster vans. Inspect the van thoroughly and make sure the engine and other components are in good working order before purchasing.

Designing and Planning Your Build

After selecting a van, it's time to start designing the layout and making a plan. Consider how you intend to use the van. Will it be a weekend adventure mobile or a full-time residence? What appliances and furnishings do you require? Sketch out a basic floor plan, mapping locations for key elements like the bed, storage, water system, electrical system, and appliances.

Research which materials work best for van builds by reading forums and looking at other DIY camper van projects. Lightweight, mold/mildew resistant materials are ideal for van builds. Once you've decided on a layout and materials list, draw up detailed plans and accumulate all the necessary building supplies before beginning the build.

Constructing the Base Camper Van Frame

With the design complete, it's time to start the exciting process of constructing your DIY camper van. One of the first steps is building out the base framing that everything else will attach to. Many builders prefer using wood like plywood for the subfloor and walls. Plywood offers durability at a reasonable price point. For the subfloor, use at least 5/8” thick plywood. Some builders double up the plywood for extra strength.

Measure the van floor space and cut plywood boards to size. Use self-tapping screws to anchor the plywood boards into the van’s corrugated metal flooring. Take care when drilling pilot holes to avoid damaging components underneath. Leave small gaps between the plywood sheets for flexibility. Use wood glue and dowels to join plywood edges for a smoother surface.

Insulating the subfloor can help regulate interior temperatures. Reflective foam board insulation adds a thermal barrier without taking up much interior space. Adhere foam panels to the plywood before enclosing the subfloor with tongue and groove boards for a finished look.

Installing Solar Power in a DIY Van

Having access to electricity gives you more freedom and comfort when living the van life. Solar power lets you harness free renewable energy from the sun to run appliances, lights, and electronics on the road. Follow these steps to install solar power in your DIY camper van:

1. Determine electricity needs. Decide which devices and appliances you want to run and estimate total power demand.
2. Select solar components. You'll need solar panels, solar charge controller, inverter, battery bank, wiring, fuses/breakers, and mounting equipment.
3. Mount solar panels to roof. Attach aluminum rails to roof and bolt panels to the rails with securing clamps. Waterproof all penetrations.
4. Install wiring and components. Run wires from panels to charge controller, to battery bank, and to electrical outlets around the van.
5. Connect and test system. Make all final connections then test solar system to confirm proper functioning.

Flexible solar panels are well-suited for curved van roofs. For a 300W system, consider three 100W Renogy monocrystalline panels. Use an adjustable tilt mounting system so you can change the panel angle as needed. MPPT solar charge controllers offer high efficiency charging. For the battery bank, use deep cycle AGM or lithium batteries designed for solar usage and frequent discharges.

Building Out the Camper Van Interior

With the base framing in place, it’s time to focus on the creature comforts that will make your van feel like home. Most van builds incorporate a combination of fixed cabinetry and multipurpose modular furniture for flexible use of space. Consider the following elements to include in your camper van interior build:

Bed Platform Frame

One of the priorities for any campervan is a place to sleep! Many builders devote the entire back area of the van to a bed platform. Build a framework from plywood or lumber to elevate the bed off the floor. Attach supports directly to the van walls/floor. You can either permanently attach a mattress to the platform or design it to accommodate removable cushions for daytime storage.

Kitchen Cabinetry

The kitchen is a critical component in a campervan build. Cabinetry provides storage for cooking supplies, utensils, food, etc. Design cabinets to fit around or underneath appliances like the sink, stove, and fridge/cooler. Use moisture resistant cabinet construction board and outdoor-rated adhesives that can withstand humidity and temperature fluctuations inside the van.

Electrical and Lighting

An electrician can help you wire up outlets, lighting fixtures, fans, and other appliances throughout the van interior. Use marine-grade switches, outlets, and wiring suitable for mobile applications. Strategically place LED lights for task lighting over the kitchen, reading lights near the bed, ambient lighting along ceilings or walls, and dimmable general interior lighting.

Plumbing System

Plumbing allows you to have running water in your van. Install a small fresh water tank under the van. Use flexible tubing to run water lines from the tank to the sink fixture and water pump. An on-demand RV water heater can provide hot water. Add a basic shower if desired. For wastewater, either collect in a gray tank or dispose of in approved facilities.

Multipurpose Furniture

Well-designed multipurpose furniture lets you get the most out of limited interior van space. A modular sofa that converts into a guest bed is a popular choice. Other options include fold-out tables, rotating/reclining front seats, and storage benches with lift-up lids. Get creative with custom DIY furniture built specifically for your van.

Finishing Touches on a Van Conversion

With the major systems installed, it's time to add those finishing touches that make your van feel cozy. Part of designing your own campervan is choosing a unique style and color scheme. Here are some ideas for finishing touches:

Insulation

Insulate the ceiling and walls to improve temperature regulation and sound dampening. Spray foam insulation offers the best R-value per inch but requires special equipment. Rigid foam boards also work well. Use fire-retardant insulation materials.

Wall Paneling

Wall paneling gives your van interior an attractive finished look. Many DIY builders use affordable pine tongue and groove boards. More moisture-resistant options include vinyl panels, reclaimed barn wood, or laminate sheets. Apply adhesive or screws to attach the paneling to van walls.

Flooring

Durable vinyl sheet flooring works well for van builds. Self-adhesive vinyl comes in wood grain, tile, or solid color patterns. Snap-together vinyl plank flooring is also an easy DIY flooring option. Make sure to prep the subfloor properly before installing vinyl flooring in a moisture-prone environment.

Reflective Window Covers

Movable reflective window covers allow you to block outside light. Attach custom curtains or mount retractable shade screens over van windows for privacy. Use blackout shades on windows near the bed to make it easier to sleep during bright mornings.

Decor

The right decorative touches give your campervan a homey vibe. Incorporate meaningful photos, tapestries, and artwork. Mount sconce lights, shelves, and storage bins to keep small items secure. Add houseplants or aromatic herbs for some fresh greenery while on the road.

Hitting the Road in Your New Camper Van

The magic moment finally arrives when your custom DIY campervan build is complete and ready for adventures. Before hitting the road full-time, test it out with a shakedown trip to work out any issues. Check that systems are functioning properly and make any final tweaks for optimal comfort and safety.

Now go out and enjoy the freedom of van life! Explore breathtaking natural wonders, cook dinner under starry night skies, or wake up to sunrise views from a beach parking lot. Your campervan gives you the ability to live a flexible, minimalist and eco-friendly lifestyle. The memories made traveling in your comfortable home on wheels will far outweigh the effort it took to build.

Converting your own cargo van into a campervan takes significant time and dedication. But this rewarding project allows you to design a custom mobile living space tailored precisely to your needs. With resourceful planning and solid DIY skills, you can build out a van optimized for full-time living or weekend adventure trips. Your campervan awaits - time to hit the open road!

FAQs

What are some good vans to use for a camper conversion?

The Ford Transit, Mercedes Sprinter, and Ram ProMaster are popular choices for DIY camper van conversions because of their spacious cargo areas and reliable mechanical components.

How much does it cost to build out a camper van?

A basic DIY camper van build can cost $10,000-$30,000 including the base van price. The cost varies widely based on size of van, components selected, and complexity of the build.

Is a DIY camper van suitable for full-time living?

With thoughtful design and construction, a DIY camper van can be customized to support comfortable full-time living. Key considerations are insulation, electrical system capacity, storage space, and including essential amenities.