top of page
planning van schematic main image.png

The Ultimate Van Conversion Guide

Welcome to the ultimate van conversion guide. This is your hub for our entire body of useful, detailed information on how to convert a van. We've divided the van conversion process into sections for you to follow in order, from the initial planning to the finishing touches. Each section contains a list of tools, materials, and a step-by-step guide.

Keep this page to hand as you go through your van conversion. Converting a van is a big project, but our van conversion how to guide will keep you organised and on track every step of the way.

Let's get started.

 

 

Did you know you can get a free electrical wiring diagram by signing up for The Van Conversion Newsletter? Our regular newsletter contains useful tips, build guides, promos, and updates about what's new on the site. Sign up today to stay current with everything that goes on here at The Van Conversion.

This post contains affiliate links, which means that if you click a product link and buy anything from the merchant (Amazon, eBay, etc.) we will receive a commission fee. The price you pay remains the same, affiliate link or not. By using these links, you are helping us to continue writing free educational content. To understand our policies on content, affiliate commissions, and liability, please review our Terms of Use.

Build Stages

Every van conversion is split into stages, which should be followed in order. We've split our ultimate guide on how to convert a van into a camper into 10 build stages.

plus icon.png
minus icon.png

Laying the Groundwork for Your Van Life Dream

  • Legal and insurance requirements

  • Choosing and buying a base van

  • Budgeting and project management

  • Features and supplies lists

  • Designing the van layout

van dimensions_edited.jpg

A well-planned van conversion is a successful van conversion. In this section, we'll highlight the important planning processes that you should square away leading up to the purchase of your van and the start of your build. Taking the time to lay this groundwork will give you a rock-solid starting point and avoid nasty surprises further down the line.

Our Van Conversion Mastery Course is a comprehensive, step-by-step guide to the entire process of converting a van, including:

  • Resources for planning your conversion

  • Supplies lists

  • Wiring, plumbing, carpentry, and metalwork diagrams

  • Video courses for all conversion stages

 

Start your van conversion right with the Van Conversion Mastery Course.

Legal and Insurance Requirements

Camper van insurance isn’t just an optional extra: normal car or van policies usually don’t cover fixed furniture, pop-tops, gas lines, or heating systems. A dedicated motorhome policy, however, protects both the vehicle and everything you’ve added to it, including unique benefits like overseas cover and contents insurance.

Special Considerations for DIY Conversions

It’s crucial to research insurance requirements before committing to a layout or build. Laws and insurer regulations vary by country (and by state in the US), so if your vehicle can’t be registered as a camper, you won’t be able to insure it as one. Our founder Shane learned this the hard way: he blocked off cab access with a kitchen installation and only later discovered bodily access was a requirement for a campervan policy in Ireland. Planning ahead avoids expensive fixes or bespoke insurance plans.

changing a tyre on an rv with roadside assistance

Types of Coverage

  • Third party / Liability: Legally required at a minimum, covers other people’s property if you’re at fault.

  • Collision: Pays for damage to your own camper, regardless of fault.

  • Comprehensive: Covers collisions, fire, theft, and more—often with optional add-ons.

  • Personal effects: Protects valuables in your van, such as electronics or sports equipment.

  • Emergency expenses: Helps with unexpected costs like accommodation if your van’s unusable on the road.

  • European/International cover: Extends benefits abroad.

  • Agreed value: Lets you and the insurer fix a camper’s value, factoring in all those costly modifications.

 

Factors Affecting Insurance Costs

Several key factors affect insurance costs—vehicle age and type, usage frequency, driving record, storage conditions, and security measures—while self-builds with pricier or riskier components often command higher premiums. When choosing a policy, compare reviews on sites like Trustpilot, Clearsurance (US), and Which? (UK), and seek personal recommendations from social media and forums.

 

Recommended Providers

  • US: Roamly (campervan-focused), Progressive, Foremost, Good Sam, National General

  • UK: Adrian Flux, Caravan Guard, NFU Mutual, Comfort Insurance, Principal Insurance

Image: Good Sam

Ultimately, insurance research is best done early in your build to avoid costly surprises. With the growing vanlife scene, more specialized policies are popping up all the time—so explore what’s out there, and find the coverage that fits you and your dream van best.

Our full article on campervan insurance contains much more information on this stage of converting a van, including:

  • Recommended van conversion insurance providers

  • Exclusive discounts

  • Lowering the cost of your DIY van conversion insurance policy

  • Temporary and seasonal insurance

  • Recommended comparison sites

Budgeting Your Van Conversion and Choosing the Right Base Van

Choosing the right van is the first exciting—but sometimes daunting—step in a campervan build. Before committing, think about the following:

  • Usage & Stealth: Will you park in cities (stealthy build to avoid trouble) or roam off-grid (exterior awnings and big solar panels)?

  • Full-Time vs. Part-Time: For full-time living, a high roof is essential, especially in cold or wet climates.

  • Space & Comfort: If you’re traveling with a partner, ensure your bed is long and wide enough. Insulation also reduces standing height, so consider a taller van if you expect frosty conditions.

  • Offroad and Overlanding: If you'll be traveling in countries with lots of open space where road infrastructure is limited, it's worth looking into a 4x4 van conversion. They're generally more expensive and harder to find, but if they're right for you, you'll reap the rewards.

  • Requirements: Making a list of requirements you have for your conversion will give you a clear idea in your head of the type of van you need to build.

Rent First

Try renting a camper to see if vanlife suits you. Outdoorsy (like Airbnb for campers) makes it easy to experience different layouts before you commit. You’ll learn what you love—and what you don’t need—saving money in the long run.

Image: offroadclub.ru

Budgeting

Follow a 70/30 or 60/40 split between van purchase and build, and add 30% to your build budget for wiggle room. We find that most people spend a median of €10,000 on their base vehicle (a bit more in the US), with a median of €5,000 on the conversion. Don’t forget extras like road tax, insurance, and vehicle inspections.

The graphs below show the spread of budgets for base vans and finished conversions that we saw in our 2023 Roaming Home study.

The Best Vans for Conversion

  • Mercedes Sprinter/VW Crafter: Highly reliable but more expensive.

  • Ford Transit: Very common, especially the high-roof L3H3.

  • RAM Promaster: The same size as a Sprinter, Crafter, or Transit, and the most popular van to campervan conversion in the US

  • VW Transporter: Classic, smaller, and beloved by weekend warriors.

  • Alternative Vehicles: Box vans, skoolies, and classic VWs can be cool but may require bigger budgets or special licenses.

The charts below give an overview of the most popular vans for conversion, as well as the most common years of manufacture, based on our 2023 Roaming Home study.

year and model of base van conversion charts.png

Finding a Solid Used Van

  • Check the service history and logbook.

  • Verify mileage and previous accidents.

  • Avoid outstanding finance—it becomes your debt if you buy it.

  • Ask a mechanic to inspect it thoroughly before handing over money.

Spending a bit more upfront on a dependable vehicle often saves you major repair bills later. By doing your research, setting clear goals, and testing the waters first, you’ll be well on your way to finding the perfect van.

Our full article on choosing among the best vans for conversion contains much more information on this stage of converting a van, including:

  • Requirements and features lists

  • Van cost breakdowns

  • Breakdowns of popular vans including the best small vans for camper conversion

  • Tips for buying a used van

  • Essential questions to ask and background checks to perform before you buy a van for vanlife

Project Management and Planning Your Van Conversion

Project management is vital for a successful van conversion. Not only does it save time and money, but it also helps you stay organized and reduces stress along the way. A great place to start is by setting up a proper system for note-taking and task management. This could be something like Notion—a free, all-in-one productivity app where you can build a supplies list, timeline, kanban boards, and daily to-do lists. If Notion isn’t for you, feel free to mix and match tools like Evernote, Trello, and Todoist; the key is having a solid system in place.

Shane has created a comprehensive, fully-featured Notion dashboard for making and organising your van conversion plans, including supplies lists, a timeline, kanban boards, to-do lists, and more. Check out this amazing project management tool here:

Laying Out Your Conversion

  • Create a master Supplies List with item prices, quantities, and links. This helps you estimate a rough budget.

  • Build a high-level timeline of tasks in chronological order (e.g., first “De-rust Van Interior,” last “Upholster Mattress”). Then add 30% extra time as a buffer.

  • Use deadlines to your advantage: tight timeframes can significantly boost productivity, thanks to Parkinson’s law (“Work expands to fill the time available”).

Daily To-do Lists

  • Write a manageable to-do list every evening.

  • Consider the “MIT” (Most Important Task) approach in the morning, or adopt a “1-3-5” or “1-2-3” rule for tasks of varying sizes.

  • Keep your list linked to your main project board, so you always know the “why” behind each day’s tasks.

Essential Productivity Tricks

  • Consistency: Work on your build a little bit every day, even if it’s just 30 minutes.

  • Gamification: Move tasks into “Done” on your kanban board, or drop paperclips in a jar to track your progress visibly.

  • Batching: Group similar tasks together (e.g., cut all wood first, then attach it) to save loads of time.

  • Environment Design: Keep your workshop tidy and tools easily accessible to avoid wasting time looking for gear.

  • Flow State: Minimize distractions, tackle moderately challenging tasks, and aim for extended periods of uninterrupted work to get into the zone.

  • Loss Aversion: Use something like Beeminder to bet on your own productivity—if you miss a goal, you pay.

  • Take Breaks & Get Help: Friends, family, good music, and the occasional rest can boost motivation and keep you on track.

By combining these techniques—staying consistent, leveraging the right tools, and keeping your eye on the bigger picture—you’ll transform what might feel like a massive project into a streamlined, efficient, and enjoyable journey.

Our full article on van conversion project management contains much more information on this stage of converting a van, including:

  • Step-by-step guides to creating your own camper van conversion Notion dashboard

  • Research techniques

  • Productivity strategies

  • Time budgeting tips

Designing the Layout for Your Van Conversion

Designing a campervan layout is one of the most exciting and creative parts of a van build. Like Steven Covey says in The 7 Habits of Highly Successful People, it helps to “begin with the end in mind.” By envisioning your layout upfront, you’ll stay motivated and ensure your camper is both beautiful and functional.

shane van layout collage.jpg

Five Steps to Van Design and Planning

  1. Inspiration & Concept

    • Gather ideas on Pinterest, Instagram, YouTube, or by chatting with other vanlifers.

    • Create mood boards (physical or digital) and note down features you like.

    • Make a must-have features checklist based on how you’ll use your van (full-time/part-time living, remote work, traveling alone or with a partner, cold climates, etc.).

  2. Logistics

    • Estimate costs early (van + materials + 30% for surprises).

    • Plan the project outline—Gantt charts and kanban boards give you a solid overview which you can follow and add to over the course of your van conversion.

  3. Initial Sketches & Layout

    • Sketch a rough floor plan on paper (scaling helps: 1:5 or 1:20 for metric; 1:4 or 1:24 for imperial).

    • Consider insulation thickness, bed orientation, and weight distribution.

  4. Technical Drawings & CAD

    • Software like SketchUp or Vanspace3D gives precise 3D models. Vanspace3D comes loaded with van templates and drag-and-drop features.

    • Develop wiring, water, and gas schematics, keeping safety regulations in mind.

  5. Feedback

    • Post your designs online or ask seasoned converters for tips.

    • Seek professional advice on electrics or gas, then revise if needed.

We highly recommend Vanspace3D as a tool for exploring and refining van conversion layouts. Vanspace3D allows you to create DIY camper van floor plans inside accurate 3D models of all popular base vans. The capability to drag and drop furniture modules around and save them for use in other mock-ups saves a huge amount of time and makes exploring and iterating on layouts a fun project. Check out Vanspace3D today and kickstart your van conversion.

Key Considerations

  • Working Remotely: You’ll likely need a proper table or standing desk.

  • Weather & Seasons: Plan for insulation, heaters, or extra fans if you’re venturing into extreme climates.

  • Stealth vs. Showy: City-dwellers may want a “builders van” look, while off-grid types can add visible extras like awnings.

  • Budget & Lifestyle: A big budget opens up features like heated showers or massive fridges, but simpler builds can still be awesome.

  • Family & Friends: Double beds, extra bunks, or even hammock hooks might be essential.

  • Personal Needs: From toilets and showers to library space and mood lighting, customize your van to fit who you are.

Testing the Layout

  • Measure your interior van dimensions thoroughly and lay painter’s tape down where fixtures (bed, kitchen, storage) will go.

  • If possible, place actual components or cardboard mockups inside to see how everything fits.

Renting a camper first (via Outdoorsy, for example) can help you discover what you really need—and what you can live without. By sketching, prototyping, and iterating, you’ll craft a layout that perfectly matches your travel style, budget, and sense of adventure.

Having checked these items off, you should now have a very strong foundation from which to start your van conversion into camper project. You should have a base van ready and know about the legal and insurance requirements for the van conversion process. You might already have an insurer picked out. You should have an idea of your van conversion cost, detailed in a project management dashboard along with a supplies list, initial to-do list, and timeline. Finally, you should have finalised your interior layout.

With all of this ready to go, we can start on the first stage of the build: shaping your van's exterior metalwork.

Our full article on designing van conversion layouts contains much more information on this stage of converting a van, including:

  • A pack of 30 free converted campervan blueprints

  • Inspiration boards

  • Supplies lists

  • Details on furniture dimensions

  • Tips for testing layouts for your van for vanlife

plus icon.png
minus icon.png

Shaping the Backbone of Your Camper Van

  • Emptying, cleaning, and rust-proofing your van

  • Installing windows

  • Fitting a rooftop fan

  • Fitting water, gas, solar, and mains electricity inlets

  • Awnings, ladders, and spare wheel carriers

Now that you've got a van sitting in your driveway and a plan for the conversion, we can start the build. In this stage of our van conversion guide, we'll be cutting holes in the van's metalwork and fitting things like windows, roof vents, and inlets for electrical connections, water, and gas. We'll finish with optional extras like a roof rack for a van, ladders, and awnings. You can't cut into your van once it's insulated, so make sure you already have your electrical, water, and gas systems specced, at least as far as knowing the inlets you'll need and where they'll go.

Metalwork masterclass.jpg

Our Metalwork Masterclass is a comprehensive, step-by-step guide to this stage of converting a van, including:

  • Supplies lists

  • Installation diagrams and charts

  • Video courses for all steps

 

Get your camper van conversion metalwork right first try with the Metalwork Masterclass.

Supplies List

We'll start with a top-level supplies list for this section. This isn't exhaustive, and doesn't include small items like brackets, bolts, or materials for any wooden framing you might want to do. Make sure there's a good DIY shop nearby, as you'll be doing lots of trips.

A power drill of at least 500W

HSS drill bits

A jigsaw

Metal jigsaw blades

Bi-metal hole saw set

Metal file

Anti-rust metal paint

WD40

Flexible silicone sealant

Sealant gun

A selection of clamps

Mastic/butyl tape

White spirits

Wire brush drill bits

Rust remover

Painter's tape

For drilling holes and driving screws

For drilling through metal

For cutting straight and curved lines

For cutting through metal

For cutting large circular holes in metal

For filing burrs on exposed metal

For protecting cut metal edges from rust

For lubricating metal during cutting

For sticking fittings and sealing holes

For applying sealant

For holding things in place during drying

For forming flexible watertight seals

For cleaning surfaces

For mechanically removing rust

For dissolving rust

For protecting bodywork

Clearing Out and Prepping Your Van

​The first step in the van conversion process is to prepare your van for all the work we'll be doing it. A clean, rust-free van is like a blank canvas onto which we'll paint our van modification layers. The first step is to pull everything out of the back of your van until you're left with bare metal on all four walls, the ceiling, the floor, and the doors. This might mean tearing up plywood lining or carpet. It's important to pull everything away in order to inspect your van for rust.

Next, we remove the bulkhead. Most van conversion builders choose to remove the bulkhead to open up the space between the cab and the living area, allowing more movement, better light, and easier access. In many countries, it's actually a requirement that a campervan allows free movement between the front and back to be legally registered. Check your local regulations before doing anything permanent.

Removing the bulkhead is generally straightforward—just watch out for its weight. In a Ford Transit, you’ll find T-55 torx bolts holding it in place. A sturdy socket wrench with the right torx bit is essential because these bolts are tight. For a Sprinter, the bulkhead is fixed with blind rivets; drilling through their centers will release the sheet metal.

Images: andyandjane.com

Renault Masters (and their siblings) mix torx screws with blind rivets, so you’ll be both unscrewing and drilling. The Ducato family has a blend of hex bolts, torx screws, and roundhead bolts—some bolts may need cutting with an angle grinder before you can unscrew them. Meanwhile, VW Transporters often only require removing a handful of torx screws.

Our full article on van conversion bulkhead removal contains much more information on this stage of converting a van, including:

  • Step-by-step instructions for removing the bulkhead from popular van models

  • Details on the insurance implications of removing your bulkhead

Rust Removal

Next comes rust removal. Rust is more than just a cosmetic annoyance—it’s a silent enemy capable of destroying your campervan from the ground up. Our founder Shane has personally spent £1,000 on rust removal just to keep his beloved van on the road. Trust us when we say: deal with rust ASAP.

Conduct a thorough inspection of your van, on the inside and out. This includes the most thorough inspection of the undercarriage you can, paying special attention to the wheel arches and door sills. Don't forget to pull up the carpeting in the cab footwells to check for rust here too.

Identify Rust Severity

  • Surface Rust: Easy to fix with light sanding and a rust inhibitor.

  • Scale Rust: Deeper flaking that requires grinding and filling.

  • Penetrating Rust: Holes or severely weakened metal that may need welding or part replacement.

Surface rust should be treated with sanding and rust remover, followed by a coating of anti-rust metal paint. Deeper rust needs to be cut out and repaired.

Four Repair Methods

  1. Metal Epoxy Putty

    • Sand away the rust, apply rust remover, then fill holes with epoxy putty.

    • Once cured, sand, prime (if needed), and paint.

    • Great for smaller spots and cost-effective DIY fixes.

  2. Fibreglass

    • Ideal for non-structural holes.

    • Layer fibreglass fabric and resin to create a durable patch that resists further corrosion.

  3. Body Filler (Bondo)

    • Perfect for cosmetic repairs on small-to-medium holes.

    • Sand, fill, sand again, and repaint for a smooth finish.

  4. Welding

    • Best solution for structural areas or large holes.

    • Permanently replaces rusted metal, restoring strength.

    • Requires skill (or a professional) to ensure a safe, long-lasting repair.

Checking the undercarriage, wheel arches, and door sills at the start of your build will allow you to get rust sorted before it spreads and before you build anything on top of it. Always consider professional help if rust has compromised your van’s frame beyond surface or limited scale rust.

Image: andyandjane.com

Our full article on rust treatment and removal contains much more information on this stage of converting a van, including:

  • 3 stages of rust

  • 4 methods of van rust removal

  • Recommended products

  • When to call a professional

Installing Windows and Roof Components

With the rust managed, we can move to the second item in the van conversion build order and start cutting into the van. There's no going back now. We'll start with the big holes that need to be cut for windows and roof vents.

Installing Windows for a Mobile Home

Campervan windows are a must-have: we're building a van to live in after all, and windows brighten your interior, provide fresh air, and—if you’re in the UK—are a requirement for official campervan status. In our Roaming Home 2023 study, 87% of vanlifers installed at least one window. Here’s what to consider when choosing yours:

Window Types

  • Fixed Windows: Cheapest and simplest, but offer no ventilation.

  • Sliding Windows: More affordable than awning windows, allow airflow, but can let in rain if you’re not careful with seals.

  • Awning/Hinged Windows: Swing open from the top, forming a rain canopy; pricier but reliable.

  • Vent Windows: Part fixed, part hinged flap. Highly secure and can be left open in the rain, though they’re harder to source and cost more.

Image: Campervan HQ

Van conversion windows

Thermal Performance

Windows compromise insulation—glass loses more heat than walls. Double-glazing and low-E coatings improve insulation significantly, while tinted windows keep your van cool and offer privacy. If winter travel is on the cards, fewer windows can help maintain warmth.

Other Factors

  • Tint: Blocks UV and prying eyes.

  • Material: Acrylic is lighter but often costlier; glass is cheaper but heavier.

  • Size: Big windows provide fantastic views, yet make it easier for thieves to break in, and can lead to heat loss in cold weather.

  • Number and placement: the sweet spot balances light and views with thermal efficiency, and is determined largely by climate.

Window Covers

Even double-glazed windows need some covering for both privacy and thermal efficiency. Blinds, Reflectix inserts, or dedicated insulated window covers help minimize heat transfer and condensation.

 

DIY vs. Professional Installation

  • DIY: Saves money and feels rewarding, but demands precision. You’ll need the right tools and patience to cut into your van and seal everything properly.

  • Professional: Costs typically range from £200–£500 per window, yet you get expert installation, a warranty, and peace of mind.

Images: Campervan HQ

 

Ultimately, choose windows that suit your climate, layout, and budget. Install them carefully, paying special attention to the sealing, and you'll have a solid, watertight fitting which will stand the test of time.

Our full article on campervan windows contains much more information on this stage of converting a van, including:

  • Step-by-step guide to installing windows in your camper van conversion

  • Recommended windows for Sprinter van conversions and other popular vans

  • Properties of different window types

  • Placement choice

  • Van conversion parts shops for buying your windows

Installing Roof Vents

The other crucial ventilation element in your van conversion is roof venting. Opening a window introduces some airflow, but unless you've got windows on opposite sides of the van, you won't get much flow of air through the space. Without proper ventilation, your van becomes a hot metal box, and all those smells—cooking fumes, damp clothes, musty bedding—build up until it’s unbearable. A roof vent helps keep your interior fresh, cuts down on mold (and therefore protects your insulation and woodwork), and improves overall air quality. According to our Roaming Home study, 52% of vanlifers install a powered fan to manage airflow.

Key Factors for Selecting a Campervan Fan

  • Airflow (CFM): A higher CFM means better ventilation, but may be overkill unless you’re in a very hot environment.

  • Power Consumption: Crucial for 12V systems. Popular fans like the Heng’s Vortex II and Maxxair Maxxfan Mini draw only around 2–3 amps.

  • Noise Levels: The Maxxfan Deluxe is relatively quiet on low settings (about 35 dB), while budget options can be louder (45–60 dB).

  • Unique Features:

    • Rain Shield/Sensor: Some fans (e.g., Maxxfan Deluxe) come with built-in rain shields; others (Fantastic Vent 7350) have sensors that close automatically when it rains.

    • Remote Control/Thermostat: Fans like the Maxxfan Deluxe and Fantastic Vent 7350 offer handy remotes and programmable temperature settings.

    • Reversible Airflow: Allows you to bring fresh air in or push stale air out.

Skylights & Unpowered Vents

Skylights let in a lot of natural light from above—often more effectively than side windows—and can still help hot air escape if they open. They’re budget-friendly compared to powered vents and can sometimes be upgraded with a fan kit later. Just note that some skylights are purely “windows in your roof" which don't open for ventilation, so you’ll want a shade or cover for summer heat.

Image: fogcampers.com

 

​​

Floor Vents

For proper airflow, the hot air your fan extracts must be replaced by cooler air. Installing a floor vent is a great solution, since air beneath the van is shaded and cooler. Placing a floor vent opposite your roof vent—fan at the front, floor vent at the back (or vice versa)—establishes a nice cross-breeze. Choose a louvered or rotary vent so you can close it up in colder climates, preventing heat loss.

A well-planned vent setup transforms your campervan from a sweaty, smelly box into a breezy, inviting living space. Our full article on roof vents includes a step-by-step installation guide, recommendations for the best roof van for van use, buying guides, and details on alternatives like fans, air conditioning, and evaporative coolers.

Our full article on campervan roof vents contains much more information on this stage of converting a van, including:

  • Step-by-step guide to installing a roof vent in your camper van conversion

  • Recommendations for the best roof fan for van use

  • Buying guides

  • Details on alternatives like fans, air conditioning, and evaporative coolers

Installing Inlets and Drop-out Vents

Next in the metalwork section of our DIY van conversion guide is the cutting and installation of inlets and smaller vents. Installing any kind of external inlet—shore power, solar cable, water, or gas—is essential for a functioning campervan. Despite their different purposes, the process of cutting a hole in your van and securing each inlet is strikingly similar. Here’s a concise overview of what they do and how they’re installed.

Shore Power (Mains Hook-Up)

Allows you to plug into campsite or household mains electricity. This charges your leisure batteries and powers high-consumption devices (like heaters) without draining your battery bank.

Solar Cable Entry Gland

Provides a watertight channel for solar panel cables to enter the van. Essential if you want off-grid independence and don’t fancy drilling multiple holes for each cable.

Water Inlet Socket

Lets you fill your fresh-water tank from an external tap or hose. Certain types (e.g., Truma, Whale) also connect to pressurized mains water at campsites, giving you unlimited water flow.

Gas Filling Point

Used for refilling an on-board LPG system (e.g., Gaslow). Rather than swapping cylinders, you plug a pump hose directly into your van—handy for running gas stoves, heaters, or 3-way fridges.

campervan inlets

 

​​

Drop-out Vents

It's important that we also consider the installation of drop-out vents. In the section on fans, we already discussed the installation of secondary air vents near the floor of the van to encourage airflow. Drop-out vents are installed the same way, but their purpose is the opposite. A drop-out vent allows the evacuation of dangerous, heavier-than-air gases that might leak into your van conversion if something goes wrong; LPG from your gas tank or carbon monoxide from your deisel heater or woodburning stove. A drop-out vent is a legally-required component of any LPG installation in many countries. 

Our full articles on gas, water, solar, and electrical inlets include product recommendations and comprehensive step-by-step intallation guides that you can also apply to the installation of drop-out vents.

Water inlet blog
Gas inlet
Mains hook up inlet blog

 

​​​

Other Exterior Van Modification - Awnings, Ladders, Wheel Carriers

Awnings, ladders, and spare wheel carriers are all about expanding your van’s functionality and convenience. While each accessory has a unique purpose—creating outdoor shelter, reaching the roof, or carrying a spare tire—the installation process often follows a similar drill-mark-seal pattern. Here’s how they stack up.

Awnings

An awning transforms the cramped interior of your van into a breezy, sheltered outdoor living space. It’s perfect for relaxing in the shade, cooking in the rain, or keeping doors open without letting in scorching sun. In our view, an awning is almost essential because of how it improves the vanlife experience.

awnings

Images: Thule, MoonShade

How They're Installed​

  • Choose a Location: Decide where on the side (or roof) the awning will mount, ensuring it won’t block doors or windows.

  • Mark & Drill: Position mounting brackets, mark the hole locations, then drill through the van’s metal.

  • Seal & Fasten: Treat raw edges to prevent rust and apply sealant before bolting the brackets firmly in place.

  • Attach the Awning: Secure the awning to the brackets and open it fully to confirm clearance and stability.

Our full article on van conversion awnings contains much more information on this stage of converting a van, including:

  • Product recommendations for different kinds of awning

  • A breakdown of common awning materials

  • Maintenance instructions

  • Step-by-step installation guide

 

​​​​

Ladders

A ladder grants easy access to your roof—ideal for clearing snow off solar panels, cleaning, or using a rooftop deck. Both back door ladders and side ladders mount externally.​

How They're Installed

  • Position & Mark: Hold the ladder in place, marking where the bolts will go.

  • Drill Pilot Holes: Always file and paint raw metal edges afterward.

  • Use a Backing Plate: Foam and a metal flange inside the van prevent damage to the door, spreading the load.

  • Seal & Secure: Apply sealant around bolts and tighten them up. Check for rattling once installed.

transit van with ladder and spare wheel carrier

Image: Campervan HQ

Our full article on converted campervan ladder installation contains much more information on this stage of converting a van, including:

  • Breakdowns of side-mounted vs. rear-mounted ladders

  • Product recommendations

  • Step-by-step installation guide

 

​​​​​

Spare Wheel Carriers

A spare wheel carrier is critical if your van didn’t come with one—or if the original underslung mount was removed. Mounting it on the back door keeps the wheel accessible and frees up under-van space for things like underslung water tanks.

How They're Installed

  • Select the Right Carrier: Bolt pattern must match your spare wheel.

  • Mark & Drill: Just like with ladders, locate bolt holes on the door.

  • Attach Backing Flange: A sturdy metal plate with foam padding spreads the wheel’s weight, prevents scratching, and maintains a watertight seal.

  • Seal & Tighten: Add sealant around the bolts before fully tightening. Finally, fit the wheel and consider using a protective cover.

Image: Campervan HQ

Our full article on converted campervan spare wheel carriers contains much more information on this stage of converting a van, including:

  • Breakdowns of different kinds of spare wheel carrier

  • Product recommendations

  • Step-by-step installation guide

You should now have a van that's empty, clean, and rust-free. You should have any extra windows fitted, a rooftop fan installed, and the appropriate inlets for the upcoming phases of your van conversion project. With all that done, we can move on to a really meaty stage of the build: the design and wiring up of your electrical system.

Solar cable entry gland blog
plus icon.png
minus icon.png
Energizing your Van Conversion
  • Understanding fusing and wiring

  • Choosing and installing a leisure battery

  • Setting up a solar charging system

  • Adding an inverter, split charger, and shore hook-up

  • Wiring up LED lighting and a 12V fuse box

  • Installing optional extras like air-con and a washing machine

battery_bank.jpg

With the metalwork finished, it's time to wire up your van's electrics. We'll be laying insulation on top of our electrical wiring, so make sure you've cut all the holes in your van that you want to and thoroughly tested every element of your electrical system before moving on from this stage. We'll start with planning our electrical system layout and going over wiring, grounding, and fusing. We'll then move on to the essential components of any van conversion electrical system: leisure batteries for camper vans, a solar setup for RV use, split charging, and lighting. We'll finish with optional extras like inverters, a shore power connection, air-con, and washing machines.

Electrics Masterclass.jpg

Our Electrical Masterclass is a comprehensive, step-by-step guide to this stage of converting a van, including:

  • Supplies lists

  • Wiring diagrams and component sizing calculators

  • Video courses for all steps

 

Get your camper van conversion electrics right first try with the Electrical Masterclass.

Supplies List

We'll start with a top-level supplies list for this section. This isn't exhaustive, and doesn't include all the cables, fuses, and electrical connectors you might need. Make sure there's a good electrics shop nearby, as you'll be doing lots of trips.

Did you know you can get a free electrical wiring diagram by signing up for The Van Conversion Newsletter? A wiring diagram is the basis for any electrical system, and we'll be discussing them a lot in the following section. Sign up for our newsletter and get ahead of the game with a free wiring diagram.

Leisure battery

Inverter

Split charger/DC-DC charger

Battery charger

Solar panels

Solar charge controller

Portable power station

Switch panel

12V fuse box

Isolator switch

Busbars

A selection of fuses

A selection of fuse holders

Inline breakers

Terminal clamp connectors

Battery monitor

Heavy-duty lugs

Heat shrinks

T-tap wire connectors

Crimp connectors

Wire stripping multitool

Crimping tool

Heat gun

The core of your electrical system

Converts 12V DC to mains electricity

Charges your batteries as you drive

Connects your van to mains power

Charge your leisure batteries from the sun

Manages solar input to your batteries

Portable power, flexible backup battery

Controls electrical system components

Fuses all circuits connecting to switch panel

Universal kill-switch for the system

Common wiring points for components

Failsafes for electrical systems

Hold fuses

Resettable fuse that doubles as a switch

Connect cable to leisure batteries

Allows monitoring of battery charge state

Connects cable to terminals

Protects wires & connectors after crimping

Splices one wire into the middle of another

Connects wires to 12V appliances

Cuts, strips, and crimps thinner wires

A more precise tool for crimping wires

Compresses heat shrinks on connections