Van Conversion

In the summer of 2020, I converted a van into a small campervan. During this project I applied my engineering knowledge, planning the conversion by creating a 3D CAD (Computer Aided Design) model in SolidWorks. 

Following this I converted the van over a period of 8 weeks, learning new skills in plumbing, electrics, and vehicle mechanics. This was a fun project that challenged my problem-solving skills and fuelled my enthusiasm for engineering and design.

Initially I made a 3D CAD model of the van to design the interior layout as shown below.

Once I had designed the van layout I then created a spreadsheet to plan the different stages of the build process and the materials and items I would need to buy. The build stages were stripping out the van interior, installing the new windows, wiring, insulation, cladding, timber framing, kitchen and bed installation, carpeting and decorating.

Once I had a plan and design in place I then started to order the items and materials for the first stage of the build and began to strip out the old interior as shown below.

Once the old interior was stripped out I could then start on installing the windows in the rear doors as shown below.

Once the windows were installed I then worked on installing anything that needed to be done before the insulation and interior cladding was installed. This included installing extra locks on the doors to improve the van security and a reversing camera with bluetooth stereo as shown in the pictures below. 

Following this I then installed the timber for mounting the interior cladding to and the wiring for the electrics.

I then installed the insulation into the walls and roof caveties then lined it with foil to act as a damp proof membrane as shown below.

Following this I then clad the inside of the van in pine boards and installed the floor insulation and floorboards as shown below.

Following this I made the bed. This was constructed from a fold out sofa bed that I made a timber frame for it to sit on with storage underneath. 

I then built the kitchen unit. This housed a sink and 2 burner gas hob as well as cabinets and drawers underneath as shown below.

Following this I was able to start work on installing a cabinet above the kitchen as well as finishing off the wiring and electrics as shown below.

I then finished off the plumbing by putting in the 70 litre water tank and connecting in the pump, tap and sink drain.

Next I worked on installing the drawers and cabinets under the kitchen as well as the garage compartment for bike storage at the back of the van.

Overall the van conversion was a success, taking me 8 weeks working full time over the summer of 2020. Since then I have been on many different trips in the winter and summer in the van and have only needed to make some minor changes to the layout inside along with general maintenance to the van itself.