It can be a big job to build a campervan from scratch, and it may feel overwhelming at times. However, everyone has different goals, agendas, budgets, and priorities, meaning each build will be unique.
How to Build a Campervan From Scratch in 15 Steps?
This guide outlines the 15 steps we took to build a campervan from start to finish. We aim to give you an overview so you can feel more prepared for the process that may come if you decide to build a campervan!
Table Of Contents
Step 1: Evaluate Your Situation Before You Build a Campervan
Step 2: Create a Comprehensive Plan for Your Campervan Build
Step 3: Choosing the Right Van to Build a Campervan
Step 4: Preparation: Getting Ready to Build a Campervan
Step 5: Windows & Roof Hatches: Essential Installations
Step 6: Insulation: Keeping Your Campervan Comfortable
Step 7: Wiring: Build a campervan with a good Electrical System
Step 8: Framing: Structuring Your Campervan Build
Step 9: Build Walls and Ceiling: Completing the Structure
Step 10: Flooring Options: Choosing the Best Fit for Your Campervan
Step 11: Kitchen & Bathroom: Designing Functional Spaces
Step 12: Adding Final Touches to Your Home on Wheels
Step 13: Testing Your Camper: Ensuring Everything Works
Step 14: Registration and Insurance: Legalising Your Campervan
Step 15: Ready, Set, Adventure!
Step 1: Evaluate Your Situation Before You Build a Campervan
First, evaluate your circumstances to determine if van life is worth it for you, and if building a campervan is feasible or if buying one that is already fitted out would be a better option.
Several factors may limit your choice:
Budgeting for Your Campervan Build
Everyone has a budget, which serves as a good starting point to assess your options when you decide to build a campervan. Therefore, begin by researching the cost of empty vans, semi-completed camper builds, and ready-to-go campers. Many factors can affect the cost, such as size, brand, age, mileage, the reason for sale, and supply vs. demand. You may be fortunate to find a complete camper that is no longer being used for a similar price as an empty cargo van.
Keep in mind that building a campervan from scratch could cost anywhere from €500 up to €30,000 or even more. Regardless of what price range you target, you should expect to go a bit over due to inflation, mistakes, and miscalculations along the way!
Assess Time and Space Constraints
Next, consider how soon you wish to use the camper. If you want to hit the road in just a few weeks, it may be best to look at pre-built campers or a simpler design for your self-build. Additionally, assess the available space for working on the camper and for storing it when not in use.
Local Availability: Finding Your Perfect Van
This aspect varies significantly by location. Some countries have numerous brands and models of vans available, while others have restrictions on vehicles used as campers and different costs for keeping a van on the road, depending on size and registration class. Thus, checking your local options is essential for your decision to build a campervan.
Skill Assessment: Are You Ready to Build a Campervan?
Your skill level will also play a significant role in your evaluation. For instance, do you have experience with tools and building projects? Would friends or family be willing to help? Furthermore, consider whether you plan to outsource any aspects of your build.
Gather Your Tools: Essentials for a Successful Build
If a friend or family member has a garage or a collection of tools, you may be in luck. However, tools can be expensive, affecting your budget or time. It is possible to create something amazing with limited basic tools when you build a campervan, but this often means trading between time and money. Consequently, spending more on good tools or outsourcing tasks can save you time for enjoying your self-built camper.
Step 2: Create a Comprehensive Plan for Your Campervan Build
Once you have established your options, it’s time to make a plan for building your campervan. Many services can assist with this, such as Vanspace3D, hiring a designer from Fiverr, or using a digital conversion guide. At this stage, dream big—think of all the features you’d like in your camper—but remember to prioritize them.
For example, do you want an open space that converts to a bedroom at night? Is a large kitchen important for feeding friends and family? Will you need a shower inside, or will you rely on campsites or sports centres?
Check Instagram, Pinterest, and everything related to van life for inspiration before reaching the challenging part: compromising. Most will find that some compromises are necessary, so get creative to fit your needs while living without certain luxuries.
For us, the priorities when we decided to build a campervan were:
- A fixed double bed
- An inside kitchen with a deep sink, fridge, stove, and oven
- A shower with warm water
- Easy access to the cabin
- Seats and a table for eating and working
- Lots of windows
- Water and electricity to keep us off the grid
Once you have outlined your priorities, sketch your layout. You don’t need to be an artist; starting with a template is helpful. It is essential to know where to begin and to keep these priorities in mind throughout the build.
By this point, you may have decided that a pre-built camper is the best choice for you. If you find something that meets your criteria and fits your budget, you can move on to the next step!
Step 3: Choosing the Right Van to Build a Campervan
With a realistic idea of your criteria and options in your area, it’s time to acquire a vehicle for your campervan project!
Start by messaging potential sellers, whether they are camper dealers or private sellers. Ask plenty of questions and, if possible, have the vehicle inspected by yourself and a professional before making a decision.
While the criteria from the first two steps are essential, the mechanics and overall health of the vehicle are crucial for your build. Be sure to check for any extra costs associated with the purchase, such as taxes, transfer costs, unpaid fees that may follow the vehicle, and future insurance and registration costs.
Once you’re confident in the vehicle and have reached an agreement with the seller, complete the transaction. If you’ve chosen the DIY route, get excited about the next steps to build a campervan!
Step 4: Preparation: Getting Ready to Build a Campervan
After buying your van, it’s time to start the project! Where should you begin?
Start by ordering items like insulation, windows, built-in fans, electrical components, and cables. It’s frustrating to be ready to continue building only to find you’re missing essential components to build a campervan.
First, ensure that your empty van is truly empty. Remove any wooden panels, factory cargo lights, or trims that may be in the way.
Once you can see the metal you’ll be working with, check for surface rust or scratches. These should be addressed before moving forward.
Base Repairs: Preparing Your Van
Use a small wire brush and fine sandpaper to remove rust. Afterwards, clean the area with mineral spirits and a cloth. The bare metal can then be painted with a metal primer and a topcoat, preferably matching the rest of the van. Spray cans are convenient for covering multiple areas; follow the instructions provided for drying times.
When confident that all metal is sealed, mark out your design using tape. This can help visualize the layout clearly. Using thicker tape can replicate the size of framing and panels between furniture as you build a campervan.
Step 5: Windows & Roof Hatches: Essential Installations
This step may be one of the scariest parts of building a campervan. Installing windows and roof hatches is not particularly difficult, but it can be daunting. You will need to cut significant holes into the van’s body. Therefore, ensure the locations will not interfere with the van’s framing or functionality.
After selecting locations, check the dimensions of the holes required. Most standard roof hatches are 40x40cm, but it’s always good to double-check. We decided to install a Maxxfan Deluxe and a Dometic Mini Heki for maximum ventilation.
How to Proceed
Use painter’s tape around the area you expect to cut to prevent paint chipping and achieve a neater result. Mark the size of the hole on the tape. Check twice and cut once. Use a large hole saw for the corners and a jigsaw to connect them, creating a square. Clean the edges with sandpaper and seal them with a rust-inhibiting primer and topcoat. Finally, install your windows or hatches according to the manufacturer’s instructions.
A Note on Windows
If you’re using glass windows, it’s wise to have a friend help, as they can be tricky to hold in place until secured. For plastic windows, securing them with screws works well.
Step 6: Insulation: Keeping Your Campervan Comfortable
With the windows and hatches in place, it’s time to insulate your van. The material you choose will affect the time it takes to complete this step, especially when you build a campervan.
Several options for insulation include:
- Spray Foam Insulation: Excellent R-value, but more expensive; be sure to follow all manufacturer’s instructions carefully.
- Fiberglass Rolls: Usually cheap, effective, and easy to work with.
- Reflective Foil Insulation: Good for heat reflection but may not offer the best R-value alone.
- Styrofoam Boards: Light, easy to cut and install, but require a vapour barrier.
- Armaflex: Easy to apply, effective and lightweight, although it can be relatively expensive.
We ultimately chose a combination of spray foam and Armaflex to achieve good insulation while keeping the weight down. Make sure to check the R-values of your insulation to gauge effectiveness.
Ensure that you insulate walls, roof, and floor—wherever you will sleep and work. Ensure everything is sealed, and cover your floor insulation with plywood. Don’t forget to fill in gaps with insulation to prevent cold spots and keep the interior warm.
Step 7: Wiring: Build a campervan with a good Electrical System
Before constructing the walls, it’s crucial to plan for electrical wiring and plumbing. Determine your electrical system needs, as different appliances consume varying amounts of power when you build a campervan.
Common layouts include:
- 12V System: Typically powered by batteries, charging while driving or with a solar panel.
- 230V System: Often used for normal appliances via an inverter.
- Hybrid Systems: Combining both 12V and 230V.
While planning, consider where to install wiring. Ensure everything is well-insulated and protected from moisture. Pre-plan circuit paths and use high-quality materials; investing in good cables and fuses is crucial for safety.
A typical setup includes:
- Solar panels on the roof
- Batteries stored under the bed or seat area
- A controller to manage solar input
- An inverter if you intend to use 230V appliances
This is a bit of a backwards thinking task.
- Firstly, you need an idea of what electronics you will be using. You can start by adding up your expected power consumption. This includes phone charging, lights, a fridge, and anything else that uses power. There are consumption calculators online that will allow you to fill in all of these devices and tell you exactly how much battery power you need.
- Once you know the size of battery required, you can choose between AGM or Lithium. We decided to stick with AGM though they both have pros and cons to consider. It is important to note that AGM is only usable to 50%, therefore you need at least twice the battery capacity that you intend to use.
- Next is the charging method. The main options are shore power charging, which is noted above, and solar power. There is also an option to charge while the vehicle is driving (DC-DC charger), though this is less reliable unless you intend to drive more regularly.
Once the big decisions are made, the preparations can begin. We decided to future-proof by running cables through the walls to two main points inside our van. This gave us three power sources in total. From each of those power sources, we placed conduits towards all of the places where we intended to have power consumers. Finally, we ran cables through the conduit to connect our consumers to the power supply in the later steps.
Step 8: Framing: Structuring Your Campervan Build
With insulation and wiring in place, you can start framing your campervan. This is when your design truly comes to life!
Begin with the bed frame, as this provides a solid base for the rest of your build. We chose an aluminium bed base for its high strength and low weight. Plan how the bed might convert into a seating area or provide additional storage, if necessary.
Remember the saying: measure twice, cut once.
Most framing can be made with wood. If you aim to increase structural integrity for future modifications, consider using aluminium or steel. Although more expensive, metal framing often remains aligned and withstands stress better.
Step 9: Build Walls and Ceiling: Completing the Structure
With the framing completed, cover the wall and ceiling. Plywood is a common choice for van walls due to its lightweight, affordability, and ease of use. Sand down any edges or rough areas before installation. If you plan to apply finishes like paint or vinyl, do this at this stage.
For the ceiling, consider leaving gaps between panels for insulation and ventilation, or create a more uniform look based on your design.
Step 10: Flooring Options: Choosing the Best Fit for Your Campervan
After installing walls and ceiling, focus on flooring. You can choose from floor options like vinyl, laminate, tiles, or carpet depending on your design and preferences.
Ensure the surface is clean and smooth before installation, and follow the manufacturer’s instructions for optimal results.
Step 11: Kitchen & Bathroom: Designing Functional Spaces
This part of the build is often the most exciting, especially if you plan to cook while travelling!
For the kitchen, install cabinetry, countertops, and appliances. A common layout includes a sink, stove, and fridge, all easily accessible.
When planning plumbing, consider what will work best for your needs. Some people use simple hand-pumped systems, while others opt for electric or pressurized water systems.
For the bathroom, carefully consider your layout. Some prefer separate spaces, while others opt for a wet bath. Whichever option you choose, ensure it is functional and meets your requirements.
Step 12: Adding Final Touches to Your Home on Wheels
Once the main build is complete, add the final touches to enhance your campervan. This includes:
- Furniture
- Decor
- Lighting
- Storage solutions
Think about everything from wall hooks to lighting fixtures and bedding to create a cozy and functional space.
Step 13: Testing Your Camper: Ensuring Everything Works
Before you hit the road, testing everything is crucial. Run your electrical systems to ensure they function properly. Check plumbing for leaks and confirm that all appliances work.
If you notice any issues, address them now to avoid bigger problems later.
Step 14: Registration and Insurance: Legalising Your Campervan
When your build is complete and you’re ready to hit the road, check local regulations regarding campervans. Depending on your location, you may need to register your vehicle as a camper and acquire specific insurance coverage.
Step 15: Ready, Set, Adventure!
Now that your campervan is ready and legal, it’s time to embark on your adventure. Plan your first trip and enjoy the fruits of your labour!
Conclusion
Building a campervan can be a rewarding yet challenging project. By following these steps and keeping your priorities in mind, you can create a space that meets your needs and brings you joy as you travel.
