Useful Notes

Introduction
Before You Start
Planning Stage
Sequence of Work
Tools Required
Skills and Scope

Introduction

A lot of people in the trade and press give grave warnings about trying to build your own motorcaravan, citing many disadvantages and suchlike. One of the principal reasons for producing this web site was to explode some myths and to show just what is possible given with the resources any normal person could obtain. I'm not saying it's easy, far from it, but with encouragement, information and know-how anybody could do what I did.

Throughout the conversion I made a note of the important lessons I felt I had learned at key stages. These are shown later.

Before you Start

Don't underestimate the cost of the conversion. Whilst I dismissed buiyng a new Eurovan camper on cost grounds, in the end I spent a whole hill of money, mainly due to not wanting to compromise and insisting on new components throughout. You could save a lot of money if you have a simple design and use secondhand camper equipment, eg. from an old caravan or camper.

Also don't underestimate the time taken. I'd originally planned that it would take around 400 hours, however its a year since I started and I'm not done yet. I reckon on 1000 hours, however you must allow for 'off' days and the shorter availability of daylight in the winter.

As an alternative, there are several companies who produce furniture kits, such as Leisuredrive and Reimo. There are also many companies who do 'one-off' and low volume customised conversions. Its well worth being familiar with the motorcaravan marketplace, and I'd recommend subscribing to one of the regular magazines, such as Motorcaravanning Motorhome Monthly.

Planning Stage

It is wise to obtain a lot of brochures from DIY component suppliers such as CAK, Rainbow Conversions, Reimo, etc so you have an idea of the size of typical components. I can particularly recommend the Reimo catalogue (even though it is in German-only) for the Eurovan. You have free reign of the layout, but there are several (sometimes conflicting) factors which you must take into account:

• To be a motorhome, you need a wardrobe/cupboards, permanent water storage, a bed measuring at least 6ft x 2ft and standing room somewhere. Otherwise, in the eyes of the law (and insurers), its a van!
• While you sketch out various layouts on paper, bear in mind the size of s eats, units etc so don't end up with a dinette with seats the size of infant school ones!
• Don't place equipment which requires external vents (fridge, water heater, etc) so that they become covered when doors (especially a sliding door on a panel van) are opened. Easy to do but dangerous!
• Keep a close eye on the total expected weight of the conversion, and the weight distribution. for example, place heavy items (batteries, gas bottles, kitchen units and significant furniture) in the middle, low down and evenly.
• Try and simplify the bed-making process and the number and rearrangement of cushions involved in this. A complex bed will prove a PITA on the campsite!
• Consider practical issues such as whether you can get to the fridge, toilet compartment, etc when the bed is made up or the cook is doing their job in the kitchen. Also can you get to cupboards once all the seats and cushions are installed and in use?
• Bear in mind that nearly all panel vans are too narrow to allow a transverse bed. Even if you are of 'petite' build, consider that one day you might sell the camper and therefore need at least 6ft for the bed.

After that lot, you may choose to copy a well-tried layout which you will see in professional conversions. If you do stick it out and come up with an original layout then great! I love new design!

Sequence of Work

My major worry was that I'd press into the conversion, then realise that I'd have to 'undo' a lot of my work to fit some just-remembered about component or whatever. So I planned at a detailed level the tasks ahead of me, which was constantly reviewed and updated. Here is the sequence I did work in, except for the elevating roof which I 'changed my mind' about half way through:

1. Fit windows and elevating roof (or have it fitted).
2. Fit as much as you can of the electrical system.
3. Fit underfloor equipment such as water tanks, piping, etc.
4. Fit anything under the wooden floor, such as wiring, pipework, etc. Often if you're unsure of later electrical wiring it is well worthwhile laying additional wires that can be used later.
5. Lay the insulation and floor, this is the basis for your furniture.
6. Build and fit the furniture frames, and install the relevant equipment in this, such as the hob unit, fridge, etc.
7. As you do this, complete the wiring as necessary. Also fit the lighting.
8. Complete the furniture fittings and panelling as necessary, then paint (or whatever final finish) it.
9. Install the wall panels and insulation behind.
10. Trim the walls, roof if necessary, cushions and curtains.

Tools Required

I bought many tools as I progressed. At a minimum, you'll need a decent set of screwdrivers, a drill, jigsaw, workbench of some kind, files, various spanners and pliers and an electrical crimping/cutting tool. But I possess many more and the list is long.

More importantly, a decent metal rule (or two), a set square, pencil and notebook should be always by your side. I found my little notebook invaluable throughout the conversion.

Skills and Scope

I've had to wear many hats including plumber, gas fitter, electrician, panel sprayer, joiner and seamster. Gas fitting and electrical mains are particular areas where you are advised to get things professionally checked-out, or even leave to the experts. I had my elevating roof and windows installed professionally, though in hindsight I could have installed the windows mysefl (or with a friend helping).

Some jobs appear simple yet are a major source of fustration, while other jobs are complex but very enjoyable to do. For example, I found connecting the gas services to be a particularly easy job, while the cutting of the many irregular panels to cope with the curvature of the rear took an eternity.

I found valuable guidance from Caravan Leisure in Hoylake, a small caravan accessory shop. They also undertake caravan repairs and were able to offer much useful advice in some of the more unfamiliar aspects.

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