How to Build Camper Conversions
- 1). Prepare the van by removing the handrails, seating and other components not required for the conversion. Sketch a layout for the interior furnishings. Remove the interior side panels.
Use masking tape to lay out the various components as sketched. - 2). Insulate the van from the heat, cold and noise with rigid-foam insulation. Cut the material into the necessary shape with a utility knife. Glue rigid-foam insulation to the interior sides of the panels. Fill gaps with expanding-foam insulation. Reattach the panels.
- 3). Build the main storage area from modular units with drawers. Stack the units to obtain the desired height. Construct a frame around the units with 2-by-2-inch lumber and plywood to make the bed-support platform. Stack the units on top of the plywood platform. Make the platform the dimensions of the mattress, such as 32 by 80 inches. Base the actual dimensions on the width and length of the space used for the bed/storage component.
- 4). Bolt the plywood platform to the floor. Use bolts long enough to penetrate the plywood and the thickness of the van's bed. Assemble the frame on the outside to have more working room. Reinsert the frame into the van and put in the storage units. Attach plywood on the top of the frame for the mattress support.
- 5). Construct the dining table out of plywood finished with Formica on the surfaces and the edges. Place it on the opposite side of the bed/storage unit -- towards the rear. Build a square-shape frame out of 2-by-4-inch boards. Secure the frame to a plywood platform bolted to the camper floor. Connect the far end of the table to the frame with hinges. Attach fasteners to other end to secure the table to the edge of the bed/storage frame when in use.
- 6). Follow the same techniques for building a sink with counter surface. Build storage underneath, for two potable water tanks and cooler, similar to the bed/storage unit. Install a water pump under the sink along with a container to capture water draining from the sink. Position the unit behind the driver's seat.
- 7). Connect two 6-volt RV batteries in series --- positive to positive and negative to negative -- for 12 volts. Connect the batteries to a fuse box with four fuses -- two fuses for lighting and one each for water pump and exhaust fan. Connect the two RV batteries to the vehicle battery in parallel --- negative to positive.
- 8). Install the exhaust-vent fan in the roof of the van or remove a window. Complete the conversion by covering the camper floor with carpet and padding. Conceal the storage areas with drapery. Add other accessories as desired.
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