Chevrolet Camper Conversion
Home built camper conversion completed in the fall of 2021
This project began as a way for me to go "abroad" during the COVID-19 pandemic. Anticipating a prolonged cancellation of international travel, I opted to build out a camper van and spend time travelling around the western region of the United States instead.
The basis for this project was to construct a driveable tiny home that was agile enough to maneuver up camping trails while still being comfortable enough to live out for an extended period. The project was completed in a little under 3 months in the summer of 2021.
Pictured above, the empty van with selected insulation and wall covering materials.
The van started as an empty shell, a blank canvas if you will. This was both a blessing and a curse as I had to start from square one. Because this van was originally sold as a work configuration, there was no insulation, no carpet, no windows, and no comfort. I planned to cut R-TECH foam sheeting to fit between the structural ribs of the van, and screw wood 1/4" wood veneers to act as the walls of the van. This insulation-wood sandwich would beautify the van while adding some insulation in extreme climates. The floor would have a sheet of insulation topped by a thin sheet of MDF plywood followed by a synthetic wood vinyl floor to add a cozier feel.
Once the insulation was in place, it was time to tackle the main electrical of the project. I had to complete all the elctrical before the walls went in so that most of my work would be hidden by the wood panels. Installation plans included a roof fan to add air circulation (placed where the green X is), dimmable lights, solar panels, 12v utility ports, and a secondary battery to keep my ignition and leisure systems separate. This would ensure that my two systems would never deplete each other and leave me stranded if my lights were left on.
If I were to redo this project, I would spend the extra time and money to buy more full sheets of insulation instead of patchwork filling holes that can be seen in the bottom picture.
After settling on the location of my lights and 12v access plugs, I began laying wires. I decided to wire my lights and access plugs in parallel so that each light would be independent of the others in the system. Although this was a more arduous task and involved understanding more of the electrical engineering side, it would save me many headaches down the road.
The auxiliary battery terminal was a big point of stress for me as I had never touched solar electrical and high-wattage appliances(mini-fridge and fan). After hours on YouTube, I set to the task at hand. My main two goals were to maintain organization and prepare for overload with redundant protections.
For the higher amperage connections, I opted for breaker switches to allow for easy disconnection if any maintenance was ever needed. The neon green is the solar charger and battery connection. The interior lights and outlets were wired to a car-style fusebox.
For my lights and outlets, I separated the different functions with color-coded wires. Black was my ground (-), red was my "hot" wire (+), and green was my relay function from my dimmer switch.
Overall, I'd say that as my first electrical engineering project, it was a success. I already understood a lot of the concepts through introductory classes I had taken at Cal Poly but was excited to apply my knowledge and test my skills.
All buttoned up! The bed platform was made of reclaimed 2x4s and a plywood sheet for the platform. The solar controller can be seen in the top right of this picture, with exposed wire routing. The roundness of the van's bodyline made that area extremely difficult to attach wall coverings to but I would end up opting for an over-the-counter wiring sheath to hide the majority of my work.
Then mini fridge in the center is connected to a 12 volt outlet hidden behind the bed
Underbed storage was critical to maintaining organization and keeping the van looking tidy. On the left and middle compartments, I stored clothes. The different cubbies were to help organize socks shirts pants and such. The far right was reserved for my dry pantry goods. A 12v fridge under the left counter of the kitchenette stored my perishables.
In the rear of the van, the bed flipped up in the same manner. This was my "garage" storage. Here I stored tools, spare parts, camping gear and everything for outdoor play and activities.
Dinner is served! The spice rack was built from offcuts of my bamboo countertop and my bed platform. I sourced my magnetic knife rack from Harbor Freight (it was originally marketed as a tool rack). My sheathing for my solar wires can be seen in the top right.
My kitchenette was constructed using a reclaimed drawer set that I converted into a cabinet. I installed a very rudimentary foot pump faucet, a freshwater tank, and a 5-gallon bucket for greywater disposal. The right side contained my cooking implements including a 20lb propane tank, hose adapter, cutouts for my Coleman 2 burner stove, and my utensils and dishware.
I opted for the larger propane tank and adapter as it was the same price for me to fill up the tank as it was for 2 standard Coleman camping-size tanks. As this build had a large emphasis on budget, sourcing the Craigslist tank and filling it once provided me with almost 10x the cost savings when compared to the same amount of propane in the standard travel-sized tanks.
Interior Glam Shot! Based on my tight budget, many items were sourced from secondhand sources or creatively repurposed from their initial function. The stool was from the Facebook marketplace, hats were hung on magnetic hooks from harbor freight, and the wall-mounted cubby was made using offcuts from my bed platform and kitchenette. My sink was sourced from a secondhand building material marketplace.
Exterior Glam Shot! I hope you've enjoyed this documentation of my van build. Although not perfect, I'm excited to tackle another van build when the time comes, with all the experiences and new skills that I know now.