In this blog post, we dive into the world of Affordable Campervan Conversions and show you this Volkswagen Crafter being converted into a VW Campervan. This guide on campervan conversions proves that you can transform a VW Crafter into a cosy living space without breaking the bank. Follow our step-by-step process to create your ideal budget-friendly campervan. (Watch the video).
Table of Contents
- Introduction to the Campervan Conversion
- Assessing the Van’s Condition
- Preparing the Floor
- Installing Windows: Tools and Techniques
- Sound Deadening and Insulation Importance
- Choosing the Right Insulation Materials
- Installing Sound Deadening Materials
- Adding Thermal Insulation
- Fitting the Bed Frame
- Setting Up Electrical Systems
- Installing the Diesel Heater
- Cutting Holes for the Maxxair Fan
- Constructing the Kitchen Area
- Finalizing the Interior Storage Solutions
- Adding Decorative Elements
- Testing and Troubleshooting Systems
- Finishing Touches and Aesthetic Improvements
- FAQ About Campervan Conversions
Introduction to the Campervan Conversion
We’re converting a 2019 VW Crafter van into a campervan on a budget of only £1,000 and a time frame of three weeks. This guide will show you how anyone can achieve this transformation.
Assessing the Van’s Condition
Panel Work
We started by evaluating the existing panel work. To stay within budget, we aimed to preserve as much of it as possible. Broken parts were marked for replacement.
Labeling and Removing Panels
Each piece of wood was labeled for easy reassembly. We carefully unscrewed and saved every panel and screw, ensuring we could reuse them later.
Metal Work and Floor
We examined the metal work, addressing any scratches or bare metal with paint to prevent rust. The floor was also inspected, cleaned, and repainted where necessary.
Preparing the Floor
Properly preparing the floor is essential for a successful campervan conversion. It ensures a stable and clean base for all future installations.
Cleaning and Inspecting
First, we thoroughly cleaned the floor to remove any debris or dirt. This step is crucial to ensure all adhesives and materials will bond correctly.
Using the Right Tools
We used a heavy-duty kit to handle the bolts securely. If you’re working with a partner, it’s advisable to share the workload for safety and efficiency.
Installing Windows: Tools and Techniques
Installing windows in your campervan is a key step in enhancing ventilation and natural light. Here’s how you can do it effectively.
Drilling the Frame
We started by drilling multiple small holes along the marked lines. This approach works well if you don’t have an angle grinder.
Using a Jigsaw
After drilling, we used a jigsaw with a metal blade to cut out the window frame. The blade cut through the metal smoothly, making the process straightforward.
Final Adjustments
We left small gaps at the corners to hold the panel in place until the cut was complete. This ensured the panel fell out safely once the cutting was done.
Sound Deadening and Insulation Importance
Sound deadening and insulation are crucial steps in any campervan conversion. They ensure a comfortable living environment.
Benefits of Sound Deadening
Sound deadening minimizes the noise inside the van. It helps in creating a peaceful atmosphere, essential for rest and relaxation.
- Reduces road noise
- Improves overall comfort
- Enhances audio quality inside the van
Insulation for Temperature Control
Proper insulation is vital for maintaining a stable temperature inside your campervan. It helps in keeping the van warm in winter and cool in summer.
- Prevents heat loss
- Reduces condensation
- Enhances energy efficiency
Types of Insulation
Different types of insulation materials can be used in campervan conversions. Each type has unique benefits suitable for various needs.
- Thermal liners
- Reflective insulation
- Foam boards
Choosing the Right Insulation Materials
Selecting the right insulation materials can make a significant difference in the efficiency and comfort of your campervan.
Thermal Liners
Thermal liners are excellent for reducing heat transfer. They are easy to install and provide a good balance between cost and efficiency.
- Lightweight and flexible
- Effective in reducing heat loss
- Easy to cut and fit
Reflective Insulation
Reflective insulation works by reflecting radiant heat. It’s ideal for use behind panels and in tight spaces.
- Reflects up to 97% of radiant heat
- Thin and easy to handle
- Great for walls and ceilings
Foam Boards
Foam boards are rigid insulation materials that offer excellent thermal resistance. They are perfect for floors and large flat surfaces.
- High R-value per inch
- Durable and moisture-resistant
- Provides structural support
Combining Insulation Types
Using a combination of different insulation materials can provide comprehensive coverage. It ensures maximum efficiency and comfort inside your campervan.
- Layering different materials for best results
- Addressing various parts of the van with suitable insulation
- Optimising thermal and sound insulation
Installing Sound Deadening Materials
Sound deadening is crucial for reducing noise and vibrations in your campervan conversion. It makes for a quieter and more comfortable ride.
Preparing the Panels
Start by cleaning and degreasing the panels you’ll be working on. Use a prep spray for thorough cleaning.
Cut the sound deadening material to size and peel back the adhesive backing. Begin adhering from the bottom and work your way up.
Applying the Sound Deadening
Apply the material to cover 30-50% of each panel. This significantly reduces vibrations and noise.
Don’t forget to cover the wheel arches, as they are primary sources of road noise. Ensure all hidden panels are also covered.
Testing the Effectiveness
Once applied, perform a sound test to hear the difference. The reduction in noise will be noticeable.
Continue this process until all necessary panels, including the ceiling, are sound deadened.
Adding Thermal Insulation
Thermal insulation is essential for maintaining a comfortable temperature inside your campervan. It minimizes heat transfer and condensation.
Choosing the Right Insulation
We use a closed-cell foam self-adhesive reflective barrier. This material effectively minimizes heat transfer and condensation.
Make sure you have enough material to cover every external panel in the van.
Applying the Thermal Insulation
Cut the insulation to fit each panel. Apply it carefully, ensuring all areas are covered, including hard-to-reach spots.
Be mindful not to cover access holes needed for maintenance.
Insulating with Fleece
For additional insulation, use fleece made from recycled plastic bottles. It’s eco-friendly and easy to handle.
Apply contact adhesive, wait for it to set, then press the fleece into place. Ensure all ridges and crevices are well-insulated.
Fitting the Bed Frame
Fitting the bed frame is a crucial step in campervan conversions. It provides a comfortable sleeping area and maximizes space efficiency.
Initial Setup
We began by positioning the bed frame in the desired location. This involved measuring the space to ensure a perfect fit.
Once positioned, we cut around the windows and other fixtures to accommodate the frame without obstruction.
Securing the Frame
Next, we secured the bed frame to the van’s structure. This ensures safety and stability while driving.
We used screws and brackets to attach the frame to the walls and floor of the van, making sure everything was tightly fastened.
Finishing Touches
With the frame in place, we added slats for mattress support. These slats were evenly spaced to provide a stable and comfortable base.
We also installed blinds above the bed area for privacy and light control. These blinds can be easily pulled down at night and retracted during the day.
Setting Up Electrical Systems
Setting up electrical systems is essential for powering various appliances and ensuring comfort in your campervan. Here’s how we did it.
Installing the DC to DC Charger
We started by installing a 30 amp DC to DC non-isolated Victron charger. This device helps manage the electrical load and charge the leisure batteries efficiently.
First, we connected the charger to the van’s main battery using heavy-duty cables and conduit for protection.
Running the Wiring
We ran the wiring along the floorboards and secured it with clips to prevent movement.
The wiring was then connected to the fuse box, which distributes power to various electrical components like lights, USB ports, and the diesel heater.
Connecting the Batteries
We built a secure compartment to house the leisure batteries. This compartment was designed to keep the batteries safe and accessible.
Positive and negative terminals were connected to the fuse box, allowing easy access for future connections.
Finalising the Setup
After connecting all components, we used the Victron app to configure the charger according to the battery specifications. This ensures optimal charging and battery health.
We left space for additional batteries and solar panels, which can be added later to enhance the electrical system further.
Installing the Diesel Heater
Installing a diesel heater is essential for maintaining a cozy environment in your campervan during cold weather. Here’s a step-by-step guide to get it done.
Gathering the Tools and Components
Before starting, make sure you have all the necessary tools and components. This includes the diesel heater unit, wiring harness, fuel pump, and display unit.
Connecting the Wiring
The wiring process is straightforward. Locate the plugs from the unit and connect them to the appropriate counterparts on the wiring harness. Ensure a secure connection for each plug.
Next, connect the live wire to your fuse box and the neutral wire to the ground. This will power up your diesel heater system.
Installing the Heater Unit
Position the heater unit in a suitable location, usually under the seats or in a designated compartment. Ensure it’s securely mounted to prevent any movement while driving.
Connect the fuel pump to the heater unit. Make sure to follow the manufacturer’s instructions for proper installation and safety.
Testing the System
Once everything is connected, fill the fuel tank with diesel and power up the system. Test the heater to ensure it’s working correctly and efficiently. Make any necessary adjustments to the settings.
This setup will provide reliable heating, making your campervan comfortable even in the coldest weather.
Cutting Holes for the Maxxair Fan
Installing a Maxxair fan is crucial for proper ventilation in your campervan. Follow these steps to install it correctly.
Marking and Drilling the Holes
First, draw the outline of the fan on the roof. Drill holes at each corner of the marked outline to create starting points for cutting.
Make one hole larger to accommodate the jigsaw blade. This will make it easier to start cutting the roof.
Cutting the Roof
Use a jigsaw to cut along the marked lines. Ensure you cut smoothly to avoid jagged edges. Once the hole is cut, file down any rough edges to ensure a clean finish.
After cutting, degrease the area around the hole to prepare it for sealing.
Sealing and Installing the Fan
Apply a generous amount of Sikaflex around the edges of the hole. Place the fan’s frame onto the roof and secure it with self-tapping metal screws.
Run your finger along the edges to smooth out the excess sealant and ensure a watertight fit. This helps prevent leaks.
Mounting the Fan
Drop the fan into place and secure it with the screws provided. Make sure the fan is open to access the mounting holes easily. Once mounted, connect the wiring as per the instructions.
Final Touches
After securing the fan, perform a final check to ensure everything is in place and functioning correctly. Test the fan using the remote control to verify proper operation.
This installation will significantly improve the airflow and ventilation within your campervan, making it more comfortable and livable.
Constructing the Kitchen Area
Creating a functional and stylish kitchen area is essential for any campervan conversion. This section will guide you through constructing the kitchen area with a focus on practicality and aesthetics.
Building the Framework
We started by outlining where the cabinets and drawers would be located. This involved building the support structure for the shelving units using MDF boarding.
- Cut MDF boards to the desired size
- Use Gorilla Glue and wood glue to secure the boards
- Screw the boards in place for added stability
Adding the Fascia and Trim
We opted for a copper door fascia, reminiscent of the old T5s, to add a touch of elegance. The trim pieces were painted a natural pine color to complement the fascia.
- Glue and screw the fascia onto the framework
- Paint trim pieces and attach them around the overhead storage
Installing the Sink and Tap
The sink and mixer tap were essential components of the kitchen area. We spray-painted them black for a modern look.
- Position the sink and mark the outline
- Cut the worktop to fit the sink
- Install a cold water system with a submersible pump
Final Touches
To complete the kitchen area, we added a worktop, shelves, and storage units. These elements were designed for maximum functionality and convenience.
- Install the worktop and secure it with brackets
- Add shelves and storage units for kitchen essentials
- Ensure all elements are securely fastened
Finalizing the Interior Storage Solutions
Effective storage solutions are crucial for maximizing space in your campervan. This section covers the final steps in setting up interior storage.
Creating Overhead Storage
Overhead storage is ideal for keeping items off the floor and within easy reach. We used MDF boarding and natural wood trim to create these units.
- Measure and cut MDF boards to size
- Attach the boards using wood glue and screws
- Paint and trim the units for a polished look
Installing Under-Counter Lights
We installed LED lights under the counter to enhance visibility and aesthetics. These lights were easy to install with double-sided sticky tape.
- Attach LED lights using sticky tape
- Thread the wires through pre-drilled holes
- Connect the lights to the fuse box
Setting Up the Table
A versatile table setup is essential for dining and working. We designed a table that can be easily moved and stored.
- Install a bar across the table area
- Attach clips to secure the table to the bar
- Add a table leg for additional support
Building Custom Shelves
Custom shelves were built to store small items like coffee pods. These shelves were designed to fit seamlessly into the existing framework.
- Measure and cut boards for the shelves
- Glue and screw the shelves into place
- Add faces to prevent items from falling out
Finishing Up
To complete the storage solutions, we added final touches like painting and caulking. These steps ensured a clean and professional finish.
- Paint the shelves and storage units
- Caulk any gaps or imperfections
- Install additional boards to hide wires
Adding Decorative Elements
Adding decorative elements can enhance the aesthetic appeal of your campervan and make it feel more like home. Here’s how to do it effectively.
Custom Plant Shelves
We started by building custom plant shelves. These shelves not only add a touch of nature but also serve as a unique decorative element.
Using a template, we traced and cut out the wood, then installed the shelves in the desired locations. This added a cozy, personalized touch to the interior.
Leather Handles
Leather handles were added to the cabinets to give a rustic yet modern look. They hang slightly down, adding character to the van’s interior.
These handles were easy to install and instantly upgraded the overall aesthetic of the space.
Stick-On Tiles
We used stick-on tiles for the kitchen backsplash. These tiles are easy to apply and can be trimmed to fit any space.
They added a stylish and practical element to our kitchen area, enhancing its visual appeal.
Utilizing Free Materials
We sourced free wood from Ikea’s exchange department. This wood was used to create custom doors and shelves, adding functionality and style without additional cost.
Using recycled materials is a great way to stay within budget while creating unique, personalized elements for your campervan.
Testing and Troubleshooting Systems
Testing and troubleshooting systems are crucial steps in ensuring that all components of your campervan conversion function correctly. Here’s how we approached it.
Testing the Bed Setup
After constructing the bed, we tested its functionality and comfort. This involved assembling and disassembling the bed to ensure it fit well and was stable.
We also tested it for comfort, making adjustments as needed to ensure a good night’s sleep.
Plumbing System Check
We tested the plumbing system by running the sink and checking for leaks. This involved turning on the pump and observing the water flow.
We made sure that the water drained correctly into the wastewater tank and adjusted the setup to prevent leaks.
Electrical System Testing
We tested the electrical system by connecting various devices and checking their power usage. This included the fridge, lights, and other appliances.
We monitored the power draw and ensured that the system could handle the load without issues.
Adjusting Components
Throughout the testing process, we made necessary adjustments to improve functionality. This included extending cables, securing connections, and fine-tuning the setup.
Proper planning and testing help avoid potential issues down the road and ensure a smooth, reliable operation of all systems.
Finishing Touches and Aesthetic Improvements
Adding the final touches to your campervan is what brings the entire conversion together, creating a space that feels cozy and personalized.
Installing the Fridge
We installed the 12-volt socket for the fridge, threaded the cables, and secured it in its housing area. Once powered on, the fridge worked perfectly.
Designing and Painting the Fascia
We worked on the last fascia unit, ensuring it fit perfectly, sanding the corners, and applying a couple of coats of black paint. This fascia included holes for a cupboard door and an access panel underneath.
Adding Leather Handles
Leather handles were added to the unit doors, except for one unit. These handles not only look stylish but also add a rustic touch to the van’s interior.
Table Storage System
We installed a table storage system on the back door, making the table easily accessible and secure. This was a practical addition to the overall setup.
Painting and Final Adjustments
After finalizing the fascia, we painted it and made adjustments to ensure everything fit perfectly. This included a cubby box for easy access to the heater and other components.
Decorative Elements
We added decorative elements like a VW Gunk figurine, USB chargers, and various trinkets to make the van feel more homely. These small touches made a big difference in the overall aesthetic.
FAQ About Campervan Conversions
Here are some common questions and answers about campervan conversions to help you start your project.
How much does a campervan conversion cost?
The cost of a campervan conversion can vary widely depending on the materials and components used. Our budget build aimed to stay within £1,000, including windows, trim, wood, electrics, and leisure batteries.
What license do you need to drive a campervan in the UK?
In the UK, you can drive a campervan on a standard car driving license (Category B) if it weighs up to 3,500 kg. For heavier campervans, you may need a Category C1 license.
What is the best van for campervan conversions?
The best van for campervan conversions depends on your needs and budget. Popular choices include the VW Crafter, Ford Transit, and Mercedes Sprinter due to their size, reliability, and availability of parts.
How do you insulate a campervan?
Insulating a campervan involves using materials like thermal liners, reflective insulation, and foam boards. Proper insulation helps maintain a stable temperature and reduces noise.
Is it necessary to install a diesel heater?
While not necessary, a diesel heater is highly recommended for those planning to use their campervan in colder climates. It provides reliable heating and ensures a comfortable living environment.
How do you manage electrical systems in a campervan?
Managing electrical systems involves installing components like a DC to DC charger, leisure batteries, and a fuse box. Proper wiring and configuration ensure all appliances and devices work efficiently.
