Van conversion secrets: build dream camper half price

In this ultimate guide to DIY van conversion in Australia, we walk you through the entire building process - from buying a van to applying the finishing touches. Regardless of whether you want to create a campervan for your own adventures or you want to become a vantrepreneur and make your conversion available for campervan hire in Australia - this guide covers everything!

Buying a van and converting it yourself is the best way to ensure that your campervan fits all your needs. It also means your van is unique and different from anything else you’ll see on the roads. But a DIY van conversion can seem like a giant undertaking if it is your first time.

To help you out, we’ve included step-by-step instructions, links to helpful resources, photos and much more. In this guide, you’ll learn how to:

• Choose between the best vans for a camper conversion.

• Design a campervan layout and prepare for the conversion.

• Install insulation, windows, ventilation, flooring, walls and a ceiling.

• Install an electrical system, solar panels and plumbing.

• Build furnishings such as a bed frame and cabinetry.

• Install finishing touches such as appliances, lighting and a stove.

Safety Disclaimer: We are not certified builders, carpenters, electricians or plumbers. This is only an introductory guide to van conversions so make sure to do your own in-depth research and consult appropriate professionals before beginning the build.

Step-by-step guide to DIY van conversion in Australia

1. Buy a van

Start by finding a van. As the foundation of your DIY campervan conversion, this vehicle needs to be in good condition, comfortable and large enough to live in for weeks or months at a time.

Consider the following factors before choosing a make and model of van:

• What is your budget?

• How much space do you need in your campervan?

• Where will you take the campervan (road-touring or off-grid)?

• Does the van have a design that lends itself to a DIY van conversion?

Once you’ve considered these factors, read our article on the best vans for camper conversion and choose a make and model that matches your needs. Here are some models to consider:

• Best small vans for conversion: Toyota Hiace and Hyundai iLoad.

• Best mid-sized vans for conversion: Renault Master and Mercedes Sprinter.

• Best large vans for conversion: Volkswagen Crafter and Ford Transit.

Before you commit to the purchase, hire a campervan that you are interested in through Camplify. This will help you decide between makes and models and confirm that your decision is the right one.

2. Design your campervan layout

Designing your living space is probably the most exciting stage of a DIY van conversion. But it also requires a lot of careful planning. You’ll need to work out the best way to arrange all of your features within one compact space, whilst at the same time ensuring it’s stylish, comfy and functional.

To work out the best interior design for your van, follow these steps:

1. Decide which features your floor plan should include.

2. Source small campervan interior ideas online or get the creative juices by flicking through photos of Camplify rentals.

3. Decide which popular layout you like the most (see below for links to popular make and model layouts).

4. Consult the van layout checklist in our article about designing your van layout to make sure your design ticks all the boxes.

5. Sketch your floor plan to scale to see how everything will fit together.

6. Test it out in the actual van using painter’s tape or cardboard cutouts.

For more inspiration when designing the layout of your campervan, read our articles on Hiace campervan layouts and motorhome bus layouts.

Also, read our full guide to designing your van layout.

3. Buy your DIY van conversion materials

Once you’ve bought your van, designed the layout and taken measurements, you can begin buying the construction materials for your DIY van conversion.

In Australia, hardware stores such as Bunnings and Mitre 10 are usually the best place to buy building materials for your campervan conversion (e.g. timber, screws, paint, plumbing fittings). However, if you don’t feel comfortable buying, measuring and cutting the materials to length yourself, you can always consider buying one of the best campervan conversion kits in Australia instead.

Many items that are specifically manufactured for use in campervans (e.g. roof vents, windows, portable toilets, etc.) can also be bought online from Amazon. If you can’t find what you want on Amazon, you can also try online stores that specialise in campervan parts such as Reimo Australia and RV Parts Australia.

Insulation is more affordable if it is bought directly from suppliers such as Pricewise Insulation or Insulation Depot. However, it can also be bought from hardware stores such as Bunnings at a slightly higher cost.

4. Strip out the van

Jump in the back of the van, disassemble everything and strip the cargo area back to the bare metal frame. This includes removing the flooring, wall panels, cabinets, lighting, seats and anything else fixed in the cargo area.

You want the bus to be an empty workspace so that you can access every nook and cranny of your DIY van conversion.

Also, look for any areas of rust or flaking paint and sand these areas back. If the van is old, you may also want to consider cleaning the metal frame with isopropyl alcohol before applying a few layers of anti-rust paint to any exposed metal.

Quick tip: If you find that there are holes in the floor after stripping out the van and removing screws and bolts, fill these in with a small circular piece of metal (e.g. a coin), then glue them in place with sikaflex, spray paint over them and tape down using duct tape.

5. Install roof ventilation

Ventilation is essential for any DIY van conversion in Australia and anywhere else! A roof vent or fan assists airflow through your living space, purges smells and helps moisture escape.

When choosing a ventilation setup for your van, consider the fan's energy consumption, the amount of air circulation in cubic feet per minute (CFM) and added features.

Once you’ve chosen a ventilation system, watch our video guide to installing a van roof ven and follow these steps:

1. Create a wooden frame that matches the measurements of the fan’s mounting surface. Sikaflex the frame against the ceiling of the van.

2. Drill one pilot hole in each corner of the frame.

3. On top of the van roof, lay masking tape around the cutting area to guide your cut.

4. Cut the hole in the roof using a jigsaw and metal blade.

5. Once the hole is cut, file or sand the edges so that they aren’t sharp.

6. Spray rust guard around the edges of the cut.

7. Clean the ceiling of any debris or dust using a brush and isopropyl cleaning alcohol around the edge of the cut.

8. If your roof is grooved, lay ceiling tape around the edge of the cut to create a flat surface.

9. Run marine grade silicone around the edge of the seal of your fan.

10. Fit the fan into the cut, applying pressure all the way around the edges to ensure that the silicone sticks to the roof.

11. Drill pilot holes around the edges of the fan, through the roof and into the timber frame.

12. Drill self-tapping screws through the pilot holes and into the timber frame to anchor the fan to the van roof.

13. Apply sealant to the top of the screws to prevent rusting.

14. Clean up any sikaflex that has spilled out onto the roof.

15. Have an electrician wire up the fan to the campervan’s 12V power system.

16. Screw the underside of the fan into the ceiling.

For more information, read our full guide to van ventilation.

6. Install extra windows and inlets

If you’d like some more natural light in your van, you may want to consider installing extra windows.

Installing windows on the side of your van follows an almost identical process to installing roof ventilation (see above). However, different styles of windows require different installation methods, so always refer to the manufacturer's directions.

If you want the ability to plug your campervan into 240v power mains at powered campsites, you’ll also have to install an external input on the side of the van. Again, this follows an almost identical process to installing roof ventilation and windows, just on a smaller scale. However, don’t try and wire the power inlet yourself - Australian law dictates that this job must be done by a qualified electrician.

7. Add sound-deadening

Installing sound-deadening material in your DIY van conversion will reduce the verberations and vibrations in your van whilst also helping to prevent sound from entering and leaving the campervan.

Measure how much soundproofing material you require to cover one-third of each panel around your van (including the three walls and ceiling). Any more material than this is not really necessary.

Once you know how much you need, buy a butyl sound-proofing product such as Dynamat and stick it at regular intervals throughout the inside of the metal frame, covering one-third of each wall and the ceiling.

8. Add insulation to the walls and ceiling

Australia’s stunning wilderness often goes hand in hand with extreme weather. That’s why insulation is key to creating a comfortable living space all year round in your DIY van conversion in Australia.

In summer, conduction transfers heat through the metal body of your van into the living area. And in winter, the opposite occurs and warm air escapes the interior of your van. Insulating your walls, ceiling and floor will hinder this heat transfer, making it easier to control the cabin’s temperature.

To decide which type of insulation is best for your van conversion, read our guide to van insulation and choose between popular options such as:

• Sheep wool

• Earth wool

• Foamboard

• Spray foam

• Fibreglass

• Foil board

• Reflective foil

Once you’ve chosen which type/s of insulation you will use, watch our video guide to installing insulation in your campervan conversion. Usually, the process looks like this:

1. Cut the reflective foil to fit the internal metal frame of your van.

2. Stick the reflective foil to the internal metal frame with an adhesive product like Kwik Grip.

3. Loosely pack some insulation (e.g. wool) into gaps in the metal frame.

4. Place masking tape over the insulation to hold it in place in the metal frame.

5. Fill in any remaining gaps or hard to reach places by spraying expanding foam insulation.

9. Insulate the floor and lay the subfloor

Now that your van is stripped back, it is time to insulate the floor in your DIY van conversion.

Because Australia does not experience extreme cold in winter, you do not need to go overboard on the amount of insulation you install. Too much insulation will only reduce the headroom in your campervan.

Foil board sheets and foam board sheets are good floor insulation options because they are relatively thin but effective. These can be stuck to the metal floor of your van using adhesive.

Once the floor insulation is laid, follow these steps to create and lay the subfloor:

1. In the cargo hold of the van, note where the ridges of the floor are and place a piece of tape on the wall to mark them. Once you lay the subfloor, you will need to know where these ridges are because this is what you’ll be drilling the screws into.

2. Create a template of the van floor by placing a piece of cardboard on the floor and cutting it to shape.

3. Trace the template onto your plywood sheeting.

4. Use a jigsaw to cut along this tracing, creating either one whole piece or several pieces of custom-shaped plywood (whichever works best for your van).

5. Lay the subfloor in the van and ensure that it fits snuggly to the edges.

6. Drill holes through the plywood and the metal frame of the van. The holes should align with the ridges that you marked earlier and should be made at regular intervals. Once the holes are drilled, secure the subfloor to the floor of the van using self-tapping screws.

For more information, please see our full guide to flooring your van conversion.

10. Mount solar panels on the roof

Before you can set up your electrical system, you’ll have to determine how much power it needs to provide.

Begin by checking the number of watts (W) each electrical appliance in your campervan uses, and then multiply this figure by the number of hours you expect to power it each day. This will give you the power consumption of each appliance, which is measured in watt-hours (Wh).

Once you’ve calculated the power consumption for each appliance, add up all of the Whs to get your van’s total power consumption.

Then, divide the total power consumption by the standard hours of proper sunlight per day (about six in Australia) to see how many solar panels you need.

Round up your solar panel wattage by about 20% to account for times when you are parked in shade or use more power than usual.

Now that you know which size of solar panel you need to power your DIY van conversion, you can start searching the market. Instead of shopping around for separate parts, we suggest buying one of the best solar panel kits for a campervan, which includes everything you need.

Once you’ve purchased the solar panel, follow these steps to mount them on the roof of your van:

1. Inside your van, inspect the metal frame of your ceiling and choose a blank spot that you can drill through.

2. Place the solar panels on top of the roof and note where the brackets sit. Ensure that the brackets align with a blank spot on the ceiling of the van.

3. Attach the brackets to the solar panel.

4. Drill a pilot hole through the roof, followed by the correct size hole for the bolts you are using to secure the panel to the roof.

5. Place silicone around the hole on the roof.

6. Fix the solar panel to the roof using the bolts and nuts provided. Repeat for all the brackets.

11. Set up an electrical system

The electrical system in your DIY van conversion is responsible for powering the lighting, ventilation, refrigeration, charging ports and any other electrical appliances. Most campervan conversions rely solely on a 12V power system that is powered by solar panels and a battery. However, more advanced van conversions might include a 240V power circuit that has been installed by a certified electrician.

But setting up your electrical system is the most complex and dangerous task you’ll face during your conversion. Among other things, you’ll need to know how to:

• Calculate your energy needs, battery size and number of solar panels.

• Choose the correct wire gauge.

• Find the right fuse size.

• Crimp your wires.

• Wire up your batteries, solar regulator and inverter.

• Wire up appliances such as your lighting and vent fan.

Our advice? Hire a professional sparky to install your electrical system and wire up the solar panels, regardless of whether you want a 12V or 240V system. It will give you peace of mind knowing that the electrics have been installed correctly and safely. That said, you should still understand the fundamentals of your van’s electrical system - just in case.

For more information, please see our full guide to a van electrical system setup.

12. Install lighting

When it comes to installing lights in your DIY van conversion, 12V LEDs (Light Emitting Diodes) are the best option. While you could use a higher voltage and an inverter, doing so would be less energy efficient - and you’ll want to conserve as much power as possible when camping off-grid.

As well as adding an atmospheric touch, LED lighting is also practical for van life:

• It’s affordable

• It doesn’t drain your battery

• It doesn’t radiate heat

• It lasts for around 50,000 hours

• It comes in every colour

Once an electrician has set up the 12V power system in your campervan, you can learn how to wire LEDs in your campervan with our full guide to van lighting.

13. Set up a water system

Life in your DIY van conversion demands a lot of water, from drinking to wiping down and even showering. So it is important to build a plumbing system that delivers enough water for your daily needs - without blowing the budget. While it can be as basic or elaborate as you want, note that sophisticated setups are often difficult and expensive to install.

Every campervan water system has 5 main components:

• Freshwater tank - holds clean water to be used for drinking and washing up.

• Tubing - connects the components of your water system.

• Water pump - supplies water flow with either manual or electric stimulation.

• Sink bowl and tap - allows you to fill up a glass, wash the dishes and freshen up inside.

• Greywater tank - stores any sullage that has passed through your sink.

If you want a more advanced setup that provides greater water pressure, you can consider also installing an accumulator. An accumulator also allows you to use the sink even if the pump is turned off and steadies the water pressure.

If you use an electric pump, we also recommend installing a strainer at the inlet port to prevent debris from getting in. Additionally, a filter on the pump will help keep your water supply clean.

For more information, please see our full guide to setting up a campervan water system or see below to learn about showers.

14. Optional: build a bathroom

If you want the freedom to enjoy your own private bathroom and don’t mind compromising on living space, it might be an idea to include a portable toilet in your DIY van conversion. Portable toilets are affordable and easy to install, meaning you won’t have to worry about plumbing in a built-in motorhome toilet and blackwater tank. We suggest that you devote one of the cupboards in your campervan to housing the portable toilet.

Some DIY van conversions also have a camping shower so that you can wash when camping off-grid. If you want a simple but effective shower solution, you could carry a portable solar shower or install a roof-mounted solar shower. Or if you wanted a hot shower with decent pressure, you could consider installing a gas or battery-powered camping shower at the rear of your campervan.

If you’re not sure about including a toilet and shower in your van conversion, hire a campervan with a shower and toilet and try it out for yourself.

For more information, please see our full guide to building a bathroom in a van.

15. Lay the floorboards

You’ve reached the stage of your DIY van conversion when you can lay the top floorboards.

With countless flooring types available for your campervan build, you need to consider what is stylish but also practical in van life. The best options for a campervan floor are laminate flooring, vinyl flooring or cork flooring. Avoid using heavy hardwoods or carpet.

Once you’ve chosen a style of floor, install it as per the manufacturer's instructions. This will involve measuring the area, laying the boards and cutting to size as you go. Consider whether you want to install the floor first and mount your fixtures on top or build your furniture directly on the subfloor and cut the floor around it.

For more information, please see our full guide to van flooring.

16. Build the bed platform

Now that you have lined the floor, walls and ceiling, it is time to start building your furniture. We will start with the bed platform.

First, consider whether you want to lay your bed sideways or lengthways. Also, consider what you want to store underneath the bed. Most DIY van conversions include two or three storage cabinets (one of which might be a pull-out rear kitchen or toilet slider) and a pull-out internal dining table.

Draw up a design for the bed frame, carefully taking measurements of the width and height of both the bed and the cabinets.

Using your design, build the bed frame out of treated pine. Attach the bed frame to the metal walls of the van using self-tapping screws and secure it to the floor using bottom plates.

Similar to the way that you cut a stencil for the walls and floor, create a stencil for the front and rear of the bed frame. Use this stencil when cutting the front and rear faces out of plywood. Mark the areas where you will cut out holes for the cabinets and drawers before cutting them out with a jigsaw.

If you want to have slide-out cabinets or a dining table, install sliders inside the cupboards and construct the drawers to fit. See below for more details on building and installing cabinetry.

17. Build the bulkhead

The bulkhead is the wall that separates the driver’s cabin from the living area in the campervan. You want it to be a solid and sturdy structure because it will also be used to hold cabinets and storage.

Much like your bed platform, start by building the frame out of treated pine and then create the face out of plywood.

For more information, please see our video guide to building a bulkhead for your van conversion.

18. Line the walls and ceiling

A timber ceiling and walls will fill your DIY van conversion with character. If you want your campervan to have a timeless look, we recommend using plywood sheets or tongue and groove panels.

Plywood sheeting is an affordable, quick and convenient option that can bend to the contours of your van. Alternatively, tongue and groove panels are great for creating a cosy and charming atmosphere.

Once you’ve chosen the type of timber you want to use to line the walls and ceilings, watch our video guide to installing cladding in your van conversion and follow these instructions:

1. Cut a 9mm plywood sheet into 200mm wide strips. These are known as furring or framing strips.

2. Screw the strips into the van’s metal framing at regular intervals (on both the walls and ceiling). Be careful not to drill the screws through the external sheet of the van.

3. Hold cardboard up to your target section, measuring and marking its dimensions.

4. Cut a cardboard template.

5. Test your template, trimming where necessary to get as flush a fit as possible.

6. Once you’re happy with it, trace your template onto the plywood sheeting or tongue and groove panels that you’ve pre-assembled.

7. Use a jigsaw to cut along the trace.

8. To cut out space for your window, puncture four corners with a drill bit before joining the holes with a jigsaw.

9. Test fit your timber - although your template has been trimmed, you’ll probably have to trim the timber a bit more in certain areas to make it a perfect fit.

10. Affix your timber to the framing strips using self-drilling metal screws. Just don’t screw into your van’s exterior sheet.

11. Repeat as necessary until all walls and the ceiling are covered.

For a finishing touch that will take your campervan to the next level, apply a timber stain or a coat of paint to your walls and the ceiling.

For more information, please see our full guide to van ceiling ideas and installation.

19. Install the cabinetry

When installing cabinets in a DIY van conversion, many Australians choose to use pre-fabricated options from IKEA and other furniture stores. Flatpack options will save you the time and effort of constructing your own cabinetry. Plus, some stores such as IKEA offer a service where they will design the cabinets to fit your campervan perfectly. Once the cabinets are built, they can be fixed to the framing strips on the wall using brackets and self-tapping screws.

Alternatively, if you don’t want to buy the cabinets premade, you can make them yourself out of plywood. For more information, please see our video guide to building cabinetry in your van conversion:

*Video*

Once you’ve chosen a sink and camping stove (see below), you can buy or build a benchtop to fit and install on top of your kitchen cabinets.

20. Fit a fridge

Installing a 12V fridge in your van is always a good idea, as it will keep food and drinks fresh without the cost or effort of filling a cooler with ice several times a day.

However, it’s also one of the greatest expenses for your van so you need to find one that will meet your daily demands. To narrow your search, consider the following factors:

• Budget - fridges are available at all sorts of price points, but be aware that a lower price usually means less reliability and efficiency.

• Design - does an upright, drawer or chest fridge suit your layout most?

• Capacity - how much food will your fridge need to store?

• Energy efficiency - the more efficient your refrigeration, the lower your energy demands and the longer you can camp off-grid.

• Extra features - what added touches and functions would you appreciate?

You’ll also have to choose between a thermoelectric fridge, 3-way fridge or compressor fridge. To find out the difference between these three types of fridges, please see our full guide to 12V fridges for your van.

21. Choose a camping stove

Your DIY van conversion needs a solid stove setup if you want to be able to prepare your own meals. However, there are many options on the market and it can be hard to discern the difference between each.

First, decide whether you want a built-in or portable camping stove. Also, consider whether you want to cook inside your van or outside at a slide-out kitchen.

Next, consider which camp stove fuel type is best for your build. For the sake of a DIY campervan conversion, it would probably be best to go for a lightweight butane or propane stove rather than LPG as this will minimise weight. If you have a 240V electrical system, you could also consider an induction stove.

For more information, please read our full guide on choosing a camping stove.

22. Apply the finishing touches

You’ve nearly completed your DIY van conversion and it is time to put on the finishing touches. Most of this stage is cosmetics and aesthetics and comes down to personal preference. For example, you will also have to choose a style and colour of handles and hinges to use on the cupboards and drawers. But you may also wish to hang some photos, a bookshelf or fairy lights.

Testing your DIY van conversion in Australia

After weeks of hard work completing your DIY van conversion, it’s time to hit the road and take your campervan for a trial run. Go for a weekend camping trip, test out all of its features and check whether they work as planned. You may want to tweak a few things here and there to make day-to-day living as easy and comfortable as possible.

Once you’ve made these final updates, give yourself a massive pat on the back - you’ve officially completed your DIY conversion! Welcome to van life.

But there’s still one last thing you need to do - sign up for Camplify!

Make a return on your DIY van conversion

There’s a quick and easy way to start earning a return on your DIY van conversion in Australia - when your campervan is not in use, rent it out on Camplify!

Instead of letting your campervan gather dust in the driveway, hire it out and make money from the comfort of your own home. Holidaymakers all around Australia want to hire unique van conversions just like yours!

Why Camplify?

Each year, heaps of Aussies earn up to $10,000 by hiring out their campervan through Camplify. It provides a quick and easy way to generate long-term passive income and earn a return on their investment.

And the best part is, Camplify takes care of many of the expenses involved in hiring out your vehicle, including:

• Comprehensive hire insurance.

• 24/7 NRMA nationwide breakdown cover for hirers.

• Dedicated customer support.

• It’s completely free to list your van.

If you’re interested in making money from home after you retire from the van life, why not try our earnings calculator and see how much income you could generate each year.