How to Build a Campervan? Step-by-Step Guide (+ Bonus) 🚐🛠️

If you’re wondering how to build a campervan, you’re definitely not alone. Lots of people are curious about how to start this fun project, and our step-by-step guide is here to help.

My husband and I recently built our own campervan, and we’ve learned a ton along the way. We’ve put together all the key steps to help you turn a regular van into a fully-equipped camper.

From planning your design to picking the right van and putting everything together, we’ve got you covered.

Whether you’re a DIY expert or just starting out, this guide will help you build your perfect home on wheels. Let’s dive in and get started!

Explore our curated list of 20 ingenious van life hacks!

Table of Contents

1. How to Build a Campervan: Getting Started

Choosing Your Layout

If you’re wondering how to build a campervan, the first step is to choose a layout that fits your needs. The layout will influence everything else, so it’s a big decision!

This is the stage where you’ll figure out the general idea, sketch out your design, and maybe even try a prototype. Take your time with this part, as it’ll shape the rest of your build.

Also, remember that space is limited—unless you’re converting a bus, not everything will fit, so plan wisely!

Here’s what to consider when picking the right van build layout for you:

Bed Size and Orientation: Decide how big you want your bed and whether you’d like it positioned across or along the van. This affects the rest of the van’s layout and should be one of the first decisions you make.
Bathroom and Shower: Think about whether you want a bathroom and shower. While convenient, they take up a lot of space and can be tricky to install.
Number of Passengers: Plan how many people will be traveling with you and if you need extra seating. More seats mean less room for other amenities.
Kitchen Space: Figure out how much space you’ll need for cooking. Most layouts include a kitchen area with a sink and hob, often near the sliding door.
Seating and Workspaces: If you plan to work or spend lots of time inside, you’ll need comfy seating and table space. Many layouts use a single table for dining and work, and rotating the front seats toward the living area is a popular option.
Garage Space: If you need to carry large items like bikes or sports gear, think about how much garage space you’ll need. This will influence your overall design.
Weight Limits: Besides fitting everything inside, you also need to consider your van’s weight. In Europe, campervans are limited to 3.5 tons, while in the U.S., the limit is a bit higher.

Our Build

In our van build, we designed a pull-out bed that’s 180 cm x 200 cm (70.9 inches x 78.7 inches), giving us plenty of space to sleep across the van. Building it took some work, but the end result was totally worth it.

We also included a compact bathroom with a shower and toilet, fitting neatly into a 100 cm x 60 cm (39.4 inches x 23.6 inches) space, so you can freshen up on the go.

For cooking and dining, we have a kitchen cabinet that’s 120 cm x 65 cm (47.2 inches x 25.6 inches) paired with a folding table measuring 60 cm x 45 cm (23.6 inches x 17.7 inches), providing just the right amount of room for meal prep and eating.

There are two seats, each 80 cm wide (31.5 inches), and a movable table sized 50 cm x 70 cm (19.7 inches x 27.6 inches) for working or relaxing. We also have one driving position and a swivel passenger seat for extra flexibility on the road.

2. Choosing the Best Van for Your Conversion

The next step in how to build a campervan is choosing the right van, as it’s crucial for creating your dream home on wheels.

There are lots of models out there, but the dimensions and engine are the most important things to think about. Here are the top 3 types of vans to consider:

The Triplets: Ducato, Boxer, Jumper (US: Ram Promaster)

When it comes to choosing the right van for your build, the Triplets (Fiat Ducato, Peugeot Boxer, and Citroen Jumper) are the top choices for many reasons.

First off, these vans are built on the same platform, so they have identical dimensions. This makes it easy to find accessories and parts that fit all of them.

They also offer various engine options to suit your needs. Just keep in mind that the Ram Promaster is the US equivalent of the Ducato, but not all sizes are available.

The wider box of the Triplets allows for a comfortable bed placement across the van. For taller people (over 195 cm or 76.8 inches), you’ll need the highest version to fit comfortably.

These factors make the Triplets the go-to choice for most campervan builders.

Ford Transit

The Ford Transit is a versatile option with several base variants, like the jumbo model and 4×4 model. It’s great if you want a bed inside the van, prefer a 4×4, or are looking for a newer model with an engine below 2.0 liters.

Mercedes Sprinter and Volkswagen Crafter

For a really big build, the Mercedes Sprinter and Volkswagen Crafter are perfect. They’re long but narrower, giving you more space for customization.

Our Choice

We went with the Peugeot Boxer because it has plenty of space, especially for taller folks. The 2.0L engine also helps keep excise duties down.

Plus, it’s got the best range of accessories, which makes it a solid choice for building a campervan.

3. Transforming Your Van’s Cargo Space

Cutting Holes for Windows

Starting the van build process by cutting holes for windows is a great way to improve the comfort and functionality of your cargo space.

Common Window Options

Some common options include large windows along the sliding side door, roof windows, and ventilation systems like the MaxxAir MaxxFan.

Our Choices

For our campervan, we chose a campervan side window, a MaxxAir MaxxFan, and two small windows (80 cm x 20 cm or 31.5 inches x 7.9 inches) at the rear of the bed to improve airflow.

Adding Comfort and Self-Sufficiency

To make your campervan comfortable and self-sufficient, consider adding features like a water inlet and external charging sockets.

Installing a small vent in the bathroom and a 4G + WiFi antenna on the roof can also enhance your mobile living experience.

Renewable Energy

Many modern campervans come with solar panels for renewable energy. If you go this route, make sure to install a grommet for cables between the panels and the solar charger.

Plan ahead and pick the right accessories to make your campervan feel like home.

4. Insulating Your Campervan

Year-Round vs. Seasonal Use

When insulating your van, one of the first things to consider is whether you’ll use it year-round or just in warmer months. Good insulation will keep your van cozy in winter and prevent it from getting too hot in the summer.

Reducing Condensation

Proper insulation also helps reduce condensation, which can form when there’s a big temperature difference between the inside and outside. For year-round use, thicker insulation, especially for the floors, is recommended.

Importance of Insulation

Insulation is essential for keeping the temperature comfortable inside and preventing water vapor from building up on the walls.

Without it, temperature differences can cause moisture to form on metal surfaces, which can lead to rust.

Materials Used

For our van, we used polyethylene foam, XPS board, plywood, vinyl panels, sheep wool, PIR, and Alufox boards.

We covered the walls and ceiling with 9 mm (0.35 inches) thick wooden paneling and painted it white for a clean look.

Framing is also crucial for connecting the van’s metal structure with the interior elements.

Soundproofing

Besides thermal insulation, butyl mats help reduce noise. But since they’re heavy, make sure to balance soundproofing with the weight of the van.

5. Powering Your Campervan

Essential Power Needs

Electricity in your campervan is a must—not just for lights, but also to run things like the water pump and heating. Without it, your van wouldn’t be able to function properly.

Power System Components

Your campervan’s power system has two key parts: things that charge the battery (like solar panels) and things that use electricity (like the fridge or charging ports).

Hotel Battery

The hotel battery is the link between these two. It’s separate from the car’s main battery. When it’s charged, you can power your devices. Just remember, since it has a limited capacity, you’ll need to recharge it regularly.

Our Setup

For our campervan, we went with a 200 Ah battery, 350 W solar panels, and a converter that charges from an external 230 V source and the alternator while we’re driving.

This setup keeps us powered up, even when we’re using things like computers or the fridge.

Power Options

In a campervan, you can power your devices using either 12 V direct current from the battery or 230 V alternating current from the converter.

Connecting devices directly to the battery is simple and safe, while using 230 V allows you to plug in devices that require a regular home socket.

6. Setting Up Water, Gas, and Heating in Your Campervan

Installing a clean water tank and a water pump is key for having running water in your campervan. The pump pulls water from the tank and sends it through pipes to the tap or shower.

If you’re after hot water, you can add a boiler or flow heater to the system. These usually run on gas or fuel from the car’s tank and can heat the whole living area.

Don’t forget to properly discharge all used water, or gray water, into a gray water tank, which is typically mounted under the van.

7. Choosing the Perfect Bed Setup for Your Campervan

Fixed Bed

If you’re under 180 cm (6 ft) tall, a fixed bed is probably the most comfortable choice.

It’s permanently mounted to the van’s structure and usually 75-100 cm (2.5-3.3 ft) above the floor. This setup offers ample space for water modules, electrics, and garage storage, and is simpler to build.

Pull-Out Bed

For taller individuals, a pull-out bed might be a better option. It requires parts to slide and unfold, making it more complex but saving space during the day.

Dinette Setup

A dinette setup gives you the most space to relax and unwind, though it does mean sacrificing a bit of your garage storage.

Other Bed Options

If you’re after something different, a Murphy bed or a bed that lowers from the ceiling could work as great alternatives.

Our Design

In our van, the bed is cleverly positioned above the seats and table, supported by a Lagun leg.

These seats aren’t meant for driving, but they offer plenty of storage and are perfect for meals or working when you’re parked. Plus, the table swivels, making it easy to create flexible eating and working spaces.

Additional Seating

If you need extra seats with seat belts for driving, an authorized company will need to handle the installation.

8. Building a Functional Kitchen in Your Campervan

Kitchen Requirements

In Poland, it’s a legal requirement for RVs to have a designated space for preparing meals. A typical kitchen module includes a sink, a worktop, a gas plate, as well as cabinets and drawers for storing kitchen utensils and food.

Our cabinet walls are made of plywood, and we chose a 2 cm (0.78 inches) oak top.

Refrigerator

In addition to cabinets, it’s important to plan for a refrigerator. Portable and camper refrigerators are available, but for longer trips, a 12 V camper fridge is recommended.

Our Kitchen Setup

For our kitchen setup, we used non-camper solutions, including a spacious steel sink, a large pull-out faucet, and a gas plate without an open flame.

9. Designing a Campervan Bathroom

Why Include a Bathroom?

While a bathroom in a campervan is optional, many people opt for one to add extra comfort and independence on the road.

Installing Shower and Toilet

You can install a shower and toilet in your campervan to avoid relying on public facilities at rest stops and campsites.

In our campervan, the bathroom measures 100 cm x 60 cm (39.4 inches x 23.6 inches), with a 60 cm x 60 cm (23.6 inches x 23.6 inches) shower tray and a waterproof toilet.

The toilet can double as a shower by simply sliding the door closed.

Construction Materials and Design

We built our shower from plywood and coated it with yacht paint for full waterproofing.

We used standard doors for entry, but alternatives include camper-specific doors or plexiglass walls. Pay close attention to corners and connection points to ensure a watertight seal.

Choosing the Right Toilet

While chemical toilets are common in RV, we chose the Nature’s Head composting toilet for its eco-friendliness and ease of use. Though it may be more expensive, it is a practical and effective choice.

10. Adding Personal Touches

How to build a campervan is more than just the construction—it’s about making it feel like home and reflecting your personal style.

We decided to build our own campervan mainly to avoid the generic feel of factory-built RVs. We wanted a space that felt cozy and beautiful, with natural materials, calming colors, and unique details.

We went for a coastal boho vibe, blending natural elements with beachy decor. For example, we added white pillows that look like beach baskets and hat hangers, plus other small touches that tie it all together.

While we kept things simple with standard solutions for electrics and water systems, we picked out classic interior accessories to give the campervan the exact vibe we were going for.

11. Must-Have Campervan Accessories

When building our campervan, we made sure to include a bunch of accessories that are super useful for traveling but don’t need to be mounted inside the van.

We’ve got things like camping chairs, a fold-out table, a yoga mat, thermal window mats, and cozy pillows and blankets that match the interior vibe.

We also packed some practical kitchen and bathroom accessories for life on the road.

For water refilling, we use a hose with different tap tips, and we carry a 230 V power cable for electricity.

At campsites, we use leveling driveways, plus we always keep a basic set of tools on hand for any van issues that might pop up.

12. Registering Your Campervan Conversion

When learning how to build a campervan, the final step is to re-register it as an RV.

For example, in Poland, you’ll need to meet basic RV requirements, like having a sleeping area, a place to prepare meals, a sitting area, and a table that can be taken down when driving.

You’ll also need to pass a technical examination, weigh the vehicle, pay excise duty, and visit the right office. While this might sound a bit overwhelming, it’s manageable with the right prep.

Just keep in mind that regulations can vary by country, so make sure to check what’s needed in your area before you start.

With the right info and a bit of effort, you’ll be able to successfully register your campervan as an RV and hit the road!

BONUS: Key Skills You Need for a Successful Van-to-Camper Conversion

How to build a campervan isn’t the easiest task, but with the right resources and a bit of patience, you can pick up everything you need to know as you go along.

Safety First

Safety is a must in any construction project, so be sure to read up on basic work techniques and always wear your personal protective equipment.

Woodworking

Woodworking is super important since most of the stuff in a campervan is custom-built. To get started, check out books or YouTube channels dedicated to woodworking.

With a few basic tools and some knowledge of wood joints and assembly methods, you’ll be able to build your own cabinets with ease and satisfaction.

Electricity and Electronics

Electricity and electronics can be tricky, but there are always people you can reach out to for help with the design or installation.

If you want to take it on yourself, start by learning about fixed and alternating current, picking the right wires, installing fuses, and connecting components.

Always be sure to read the device instructions for installation guidance.

Plumbing

Plumbing is pretty simple if you make sure high-pressure parts (like fresh water) don’t leak and that outflow parts are connected properly. Start by learning how the components connect and test your system outside the van.

A water tank, pump, and hoses are a great way to test. Don’t forget to do leakage tests before installing the final system in the van.

Gas Assembly

Gas assembly is best left to the specialists because gas leaks can have serious consequences. If you decide to do it yourself, make sure you know how to connect gas elements and get the right tools to check the system’s tightness.

Metalworking

Metalworking means cutting holes in your van, so make sure you’re using quality tools.

Using poor-quality blades or jigsaws can mess up the van’s sheets, so it’s worth investing in good tools to make the job smoother and reduce the risk of mistakes.

Car Mechanics

If you want to handle this yourself, start by learning about fixed and alternating current, selecting wires, installing fuses, and connecting components. Always read the device instructions for proper installation.

How to Build a Campervan: Frequently Asked Questions

How do you insulate a van?

If you’re wondering what materials to use for your campervan insulation, aim for ones that offer great thermal insulationand are non-flammable and non-toxic.

While not every material ticks all these boxes, it’s all about finding what works best for your needs.

Common insulation materials for campervans include PUR foam, XPS and PIR boards, polyurethane foam, and mineral or sheep wool.

Choosing the right insulation will help keep your campervan comfy and energy-efficient throughout the year.

What are the best materials for building a campervan?

When building campervan cabinets, choosing the right materials is key. Birch plywood is a popular option, available in various thicknesses depending on its use:

3 mm (0.12 inches) is great for decorative elements.
6.5 mm (0.26 inches) works well for lightweight cabinets and walls.
12 mm (0.47 inches) is perfect for most cabinets.
18 mm (0.71 inches) is best for high-stress areas like seats.

You can also use wooden or aluminum profiles as a base and mount camper plywood on top. This method is common for cargo cabinets and shower walls.

When picking materials, keep weight, durability, and aesthetics in mind.

With the right materials and careful planning, your campervan cabinets will be both functional and stylish.

What tools should you use to design a campervan?

There are plenty of tools to help design your campervan. Here are a few that might come in handy:

Pinterest: A great platform for finding inspiration, ideas, and creating mood boards for your campervan project.
SketchUp: A free online design tool that’s perfect for designing cabinets or the entire van layout. It might take some practice, but there are tons of tutorials to help you get started.
Pen and Paper: Perfect for simple sketches and noting down exact measurements (make sure to double-check those!).
Cardboard, Plywood Templates, etc.: Great for making mock-ups of your campervan’s structure or cutting identical parts.
Excel or Google Spreadsheets: Super useful for estimating costs and keeping track of your budget during the build process.

How much does it cost to convert a van into a campervan?

The total cost of converting a van into a campervan depends on things like materials, size, and how much you modify. In our case, it came to about 16,000 Euro, not including the vehicle. Here’s the breakdown:

Water, gas, and heating system: ~4,500 Euro
Electrical systems, panels, and electronics: ~3,000 Euro
Insulation, windows, and ventilation: ~2,500 Euro
Cabinets and interior fittings: ~2,500 Euro
Bathroom and kitchen: ~3,000 Euro

How long does it take to convert a van to a camper?

The duration of converting a van to a camper depends on a few things, like the size of the camper, the layout you choose, the workforce, and how much time you can commit.

In our case, the whole process took about 8 months, and we worked on it mainly during weekends, outside of our regular hours.

Check Out Our Video On How to Build a Campervan!

How to Build a Campervan: Summary

In conclusion, building your own campervan may seem daunting at first, but with the right planning and a bit of patience, it’s totally achievable.

If you’re wondering how to build a camper van, starting with a solid plan and the right van is key.

From installing systems like electricity and water to adding cabinets and accessories, each step brings you closer to your dream van.

If you have questions along the way, don’t hesitate to reach out in the comments. You’ve got this—time to turn your campervan dreams into reality!

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How to Build a Campervan? Step-by-Step Guide (+ Bonus)