Custom Conversions
Campervans, surfer’s day-vans, catering trucks or mobile pet-groomers!
If you have a project in mind we would love to hear about it.
We custom build vans to perfectly fit various lifestyles.
It’s a process that requires getting to know you,
and finding the best options available.
If you are keen to get something built we offer
a free consultation and quotation service.
Choosing a vehicle
We don’t buy vans, but can advise on models that suit your project and budget. Looking for the right vehicle can take a long time, and it’s a good idea to start working on the layout at the same time. Initially calculate the volume of your most essential items, and then size your van around them.
The most popular range of panel vans for campervan conversion are the Ducato / Boxer / Relay / family of vehicles. They perform well under load, rarely rust & have the best fuel economy in their class. They come in a wide range of lengths and heights suitable for most projects. They are also a bit wider than most panel vans, allowing for an adult sized bed to fit width ways in the back.
Design
I love it when a plan comes together!
Having digital tools to know your space in detail is incredibly useful. Using CAD software, we can accurately visualize the end results, with all the people and possessions stored within to scale. It also helps calculate costs of materials needed.
It’s a really good way to start the project’s conversation too. There’s a little to and fro at this stage, getting things just right, before both sides are happy, and we proceed to production.
Groundwork
All second hand vans will need thorough cleaning and reverting to a basic shell. Once back to a blank canvas the first tasks tend to be quite brutal - walls removed and various holes cut for windows, vents and cables.
Like building a house, there is an incredible amount of preparation done early on that isn’t visible later. Every surface needs to be levelled, structural batons are added. Cavities filled with insulation and everything covered up attractively after.
Insulation is extremely important. We use dodomat (for sound insulation) then a mixture of eco-wool, celotex & spray foam. It’s an essential process to keep the van temperate. - Cool in Morocco, or cosy in the Alps!
Features & Layout
Now we have a blank room to fill, boundaries are marked out indicating key items (such as furniture, fridges, beds) then electric cables, water and gas lines are run around the edges.
Space and cost are the only limiting factors in kitting out a van with all the latest mod-cons. Rock’n’roll beds, combi-boilers, lithium powered convection hobs, cinema projectors! There is a never ending array of devices being designed to improve van-living.
It can be a discussion in itself and we are more than happy to recommend and advise on any new bits of kit getting approval in the community.
Furniture & Finish
All of our furniture is made bespoke. It allows us to get the most out of restricted spaces and add personal touches wherever possible
Weight of materials is a big issue. It is vital to keep your vehicle within its class (most campervans are 3.5 tonnes). So we use Birch plywood for all panels, as it is strong & durable yet incredibly lightweight.
Birch ply is a beautiful pale wood that can be finished in either a clear lacquer (showing off the grain) or a tough melamine coating in any colour or texture you can imagine.
For worktops use sustainable hardwoods, bamboo or thick coated ply. We forget about weight restrictions (for once!) as they need to cope with heat and moisture. With the right shade of wood, oil or highlighting colour it often is the focus of the whole kitchen area.
We can upholster and panel the van in any material you desire. We have a large sample library, and offer colour schemes & combinations to work with. CG can be used to help you visualise the end results, and we run test examples with actual materials along the way too.
How much does it cost?
From the descriptions above we hope you have gained some insight into the process and materials that go into a complete conversion. There are a myriad of options available, and you can go as wild as you like when kitting one out. For that reason we tend to work on a parts + labour basis.
As a rough guide, for a Boxer or Sprinter sized van, without adding anything extraordinarily lavish, the materials can total around £10-£15k. The conversion process takes around 60 full working days, so labour & other costs can reach around £15k. Purchasing a vehicle worthy of this much attention might also cost in the region of £15k.
These are very rough figures. If you don’t find them too off putting and want to convert a vehicle we would love to hear from you. We offer a free design and quotation service where we can go into details and discuss what is possible
