Do-it-yourself campervan: How to build your campervan in 7 steps
Author: Jörg Lohse
Every vanlife project starts with the search for the right vehicle. Panel vans in the "Sprinter class" have established themselves as the best basis. The permissible total weight should be at least 2.8 tonnes, preferably 3.5 tonnes, in order to have enough payload for the extension and later equipment. At the same time, however, the total weight should not exceed the latter value if the camper is to be driven with a normal class B car driving licence. It is also important to ensure that the interior is as rectangular and uniform as possible, as this makes it easier to convert. Popular base vehicles include the aforementioned Mercedes-Benz Sprinter, VW Crafter or Fiat Ducato. The manufacturer's conversion guidelines should be consulted before purchasing. These contain important specifications for the conversion, for example regarding load-bearing body parts. If you are looking at the somewhat smaller van class (e.g. the VW Transporter, Mercedes-Benz Vito or Ford Transit), you can tackle the major hurdle of "motorhome registration" without major conversion work on the body with many ready-made installation kits.
Destination motorhome licence
In order for a converted vehicle to be registered as a motorhome, certain minimum requirements must be met. According to the guidelines of the Association of Technical Inspection Authorities (VdTÜV), these include: seating with a table, sleeping accommodation (also possible by folding down the seats), a permanently installed cooker with an ignition fuse and sufficient storage space for clothing and provisions. Fittings, apart from the table, must be firmly anchored in the vehicle so that they can only be removed with tools. Fastening using wing nuts is therefore not an option. When dismantling, it is also important to ensure a balanced weight distribution that does not have a negative impact on driving behaviour.
Safety at a glance
The design features of the vehicle play an important role in the removal itself. If, for example, an existing partition wall between the driver's cab and the load compartment is removed, it should first be checked whether it is a load-bearing part. If this is the case, additional bracing would be necessary. Good insulation is essential for camper van conversions, even if you only want to be travelling in the warmer months. It not only protects against the cold, but also against heat and prevents the formation of condensation, which can lead to mould. The walls and roof in particular need to be insulated, as does the floor for year-round use. Styrofoam, rock wool or Armaflex have proven themselves as insulation materials.
Expansion and furnishing
Once the insulation is complete, the interior work follows. Tongue and groove wood panelling, for example, is suitable for the wall panelling and is easy to install. Think about cut-outs for sockets when cutting the boards to size! PVC flooring, which is robust, easy to clean and available in various designs, is ideal for flooring. Creative use of space is required for the furnishings. Many suppliers have modular solutions in their programme that can be put together according to your own ideas. Vanlife designers can now also find what they are looking for at large DIY chains. Materials that are as flame-retardant and splinter-proof as possible should be used for the interior components and should not pose any risk of injury in the event of an accident.
Be careful with gas and electricity
Special care must be taken when installing electrics, gas and heating. The electrical system must comply with VDE regulations, especially for 230-volt installations. This work is best carried out by a specialist. The gas system and any additional heating must also be installed and approved in accordance with regulations. It is essential that the ventilation, exhaust system, auxiliary heating and gas system are separated from each other. It must be possible to ventilate the driver's area and living area sufficiently.
No camper without an escape route
The entrances to the living area must be safe to use. The lowest step should not be higher than 500 millimetres. A separate entrance door to the living area must be installed on the right-hand side of the vehicle. The driver's seat should be quickly and easily accessible from the living area. Ideally, there should be at least two independent escape routes on different sides of the vehicle.
TÜV approval
Once the conversion is complete, the TÜV inspection is due. Cracks have already contacted the inspector during the planning phase. At the appointment, the vehicle manufacturer's body guidelines, test certificates for installations such as the gas system or heating and a weight calculation should be presented. Following the TÜV approval, you can then apply for a motorhome licence. This is usually worthwhile, as motorhomes are often taxed and insured more favourably than comparable vans or minibuses.
Save on insurance
The insurance company should be informed about the conversion to a motorhome. As a rule, special motorhome insurance is cheaper than a normal motor vehicle policy. In addition, comprehensive insurance for motorhomes usually also covers the permanent fixtures and fittings. The topic of "young drivers under 25" can also be interesting, as many motorhome insurance companies do not charge any surcharges here.
Keeping an eye on costs
However, a vanlife project is not really cheap. It starts with finding a suitable basic vehicle that is not a run-down vehicle with a lot of rust and dents. Vans owned by tradesmen or disused vehicles from parcel service fleets are usually ruled out. You should also take your own labour into account: Three to four weeks of pure conversion time must be calculated and it is best to call in a specialist company for gas and electricity, for example. Don't forget a well-stocked but also high-quality toolbox that is suitable for metal and woodwork. Depending on the desired equipment, the first 10,000 euros for the furnishings will soon be exceeded. Including the vehicle, you are quickly in the range where good used vehicles are already on offer. But: you can build your dream vehicle for future dream tours according to your own ideas. It's like the well-known advertising slogan: priceless!
Vanlife portraits from the MTB scene
Hannes Klausner
The former snowboard pro now sits on two wheels. What fascinates the freerider in connection with his passion for van life are the endless possibilities that await him on the road, as he describes in his blog with powerful images and words: stop, get the bike out and then "epic riding!" He designs his mobile homes together with the specialists from Castello in Austria. Hannes is currently working on a new vanlife project, which we will be reporting on shortly. Blog: timeisyourlife.com
Julia Schaefer (Hofmann)
Julia Schaefer (Hofmann) was born in Upper Franconia and has been travelling the world for 13 years on her mountain bike and often with her Land Rover in search of the most beautiful mountain bike trails. She now lives with her husband and two children in Upper Bavaria, where she runs a small campsite by a natural swimming lake. Julia has been tinkering with cars for as long as she can remember: "When I was 16, my brother and I refurbished an old Beetle from scratch. My brother also passed on the Landy bug to me. He is also the walking Land Rover encyclopaedia, without him I would often have been stranded somewhere for a long time. But thanks to the 24/7 Sebastian service hotline, I was able to repair my Landys so that I could almost always drive home." Her old Landy Series 2a was her bachelor's thesis project, on the subject of mobile minimal living with a mountain bike: with a convertible bed from 70cm to a 1.40m mattress and a folding table for eating between the seats. "I wanted to create a Land Rover," Julia explains, "in which I can store everything inside and eat when I'm travelling alone. If there are two of us, I can convert it so that the wheels are on the roof and we sleep on a wide mattress inside." Her "new" Land Rover, a 2014 Defender TD4, is her "sensible car" for long journeys and for towing trailers etc.: "A lot of people laugh at me. A car like that is not a sensible car, they say. But it is for me!" Juli has converted the Landy into a workshop car and drives it to festivals and events to give workshops: "I can live in it too, but I have to get out to eat and cook. There is a pull-out toolbox and a tool cupboard behind the sliding side window. I can store two bikes next to the bed and my EVOC World Traveller fits perfectly behind the passenger seat as a wardrobe." More about Julia at sunnyrideoflife.de
Jasper Jauch
The 2011 "Mountain Biker of the Year" was the overall winner of the German Downhill Cup in 2014 and German runner-up in 2015. Today, he trains young talent and entertains the scene with podcasts and YouTube videos. He is on the road at least 183 days out of the 365 days in a year due to his job, but he admits that he has always lived as a vanlifer: "I was a racer with no money and couldn't afford a hotel. That's why I always slept in cars or on the bus." Jasper started out in a T3 VW Bulli, followed by a T4 - both with a bed on board, and finally the Opel Vivaro. However, this eventually became too small when it was no longer just about getting from A to B cheaply. "I need an office where I can work and edit my clips. But I also need a retreat where I have time for myself." His current vehicle is a Sunlight Cliff 601 Adventure, more about this on his Instagram channel.
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Rick Zabel
The ex-professional racing cyclist, son of cycling legend Erik, designed the "Rick Edition" with Austrian van specialist Mavis. For him, it was important to combine functionality and a sense of adventure, but also to have space for bikes and equipment as well as a comfortable sleeping area. He also focussed on being self-sufficient in terms of electricity and water. In addition to "Rick", the Mavis concept also allows for other customised solutions. The basic module costs 15,900 euros including installation, while the Rick edition, which is also available from Tchibo, costs 34,900 euros. Info: mavis.one/tchibo
Book tip
Holidaying and living in a home on wheels gives you independence and makes individual wishes come true. How about a little inspiration and know-how? In "Van it Yourself" by authors Ute and Rafael Mans, vans and their owners are portrayed, supplemented by easy-to-understand instructions for small DIY projects. This book offers a treasure trove of ideas for camper van conversions: from basic considerations to loving design options that make your stay on board more enjoyable. Small DIY projects, presented in easy-to-follow steps, can be realised even without previous knowledge. Hardback; 160 pages; 29.90 euros >> buy directly here.
