Our prototype van
We are currently in the midst of our prototype build. We’ve designed a layout to accommodate a wide-array of needs that would be useful to adventurers, festival goers, campsite weekenders and tourers.
This camper is situated to be fully off-grid – utilising Victron electrical components for 12v & 230v systems, Truma D4E for hot water and heating. Gas for cooking.
Featuring a shower, spacious garage and comfortable seating area situated inside a 2015 LWB Mercedes Sprinter.
We’ve added links to the products we’ve used through our eBay ambassador programme, we receive a small commission if you purchase through these links.
a detailed look at the build process
Prep
First to do was prep, removing debris and deep cleaning the interior before work could commence.
Rust was removed with grinding, and treated with rust converter followed by an anti-corrosive primer.
Cutting
Next the cut outs were
completed for the windows
and Maxxair Fans, opting
for the measure twice – cut once approach…
You can’t add material, only take it away!
Insulating & Electrical first fix
Before insulating we’ve ran our 12v & 230v circuits, any cables that meet edges of the van chassis are ran through conduit for protection. Grounding is affixed to the chassis by removing paint on a section, affixing the respective cables with nut, bolt and washers. They are then covered with dialectic grease to protect the exposed metal.
Dodo Mat Thermo Liner Pro 15mm SE was applied on top of all panels that had been treated with Dodo Mat DEAD-EZY sound deadening.
Cavities were packed with an insulation product made of 100% recycled polyester. It will not absorb moisture in high humidity conditions and does not support mould growth.
For the flooring it has 25mm insulation boards secured between batten with CT-1 adhesive. The original subfloor is then refitted and screws are used to secure it to the batten.
Framing
We need a system to secure our ply lining and cabinetry too. Utilising 18mm ply sheets we created small strips (batten essentially) that can be secured to the vehicle chassis via self drilling flanged hexagon bolts.
Securing the bed rails was accomplished through the use of Rivet Nuts. Each individual bolt then used to secure the rails to the van chassis has a sheer strength rating far exceeding the weight of a pair of adults.
Ceiling
The ceiling has been constructed in two parts from 6mm ply. This is first painted black and then has our burned (inspired by Shou Sugi Ban) pine boards secured using CT-1 adhesive and screws from the rear of plywood.
Once manoeuvred into place it is secured through CT-1 adhesive and screws into the batten on the roof. It is supported using support props whilst the adhesive cures.
Ply lining & Flooring
6mm plywood is used to board the walls, any cavities introduced are then filled with insulation. These are secured using brad nails. LVT flooring is laid on top of underlay for comfort underfoot.
electrical
Electrical system construction begins, built onto our garage side cabinets. These will eventually have the front doors fitted for protection. Victron components are chosen for their efficiency and reliability. There are 3 methods of charging available being – Solar / Vehicle Alternator / Shore power hook up. Circuits were ran previously in the vehicle and will be connected to the board once installed in the rear of the van.
Window framing / seat box / bed rails
We frame the window utilising the batten behind the ply wall to secure our frame using wood glue & brad nails. The seat box is constructed and affixed to a base in turn secured to the batten in the floor. This will house large drawers for storage. The bedrails are constructed from reclaimed redwood and secured to the bed frame rails seen earlier. At this stage our garage cabinets have also been installed. The cabling for the electrical system is connected to its respective components. All cables are then secured to the van or rear of the cabinet to ensure safety and reduce noise from vibration.
All electrical circuits are tested to ensure safety of operation. It’s also great to now have lighting inside the van!
We’ve created knock outs seen on the right of image 2 to become cubbyholes for storing things like spices in the kitchen, and a little nook in the bedroom for small items.
Wall & overhead Cabinet
We continue the burned boards down the side of this wall incorporating them into our overhead cabinet. They are secured using CT-1 adhesive and brad nails. We’ve incorporated an LED strip into the cabinet over the seating area.
Kitchen oak worktop
This is a good time to mention our social media if you haven’t already followed us. You can follow the build progress through our instagram in the form of short video. Here Jimmy is constructing the oak worktop that we got from our friend Tim at Treesave Reclaimation. Hours of sanding have gone into turning the raw product into something we think (we may be biased) is stunning.
This is finished with Osmo Top Oil which is suitable for kitchen work tops. It is a microporous natural hardwax-oil wood finish which is extremely tough and hardwearing. It is water repellent and dirt resistant. The finish is resistant against wine, beer, cola, coffee, tea, fruit juices, milk and water. These types of liquid spillages will tightly bead on the surface without leaving any marks, simply clean by wiping with a cloth. And importantly is food safe (EN 1186).
Kitchen install
It’s looking more like a camper now! In goes the kitchen unit, fridge, sink, faucet and Thetford Triplex Oven. We’ve made a neat cut out for the sink to maximise counter space whilst not in use. The oven is plumbed to the gas locker at the rear of the van with a single run of copper with a local isolation valve to the rear of the oven. Gas dropout vents are incorporated into the cabinet below the oven that fall through the van floor. Häfele drawers will be added soon.
This van is nearing completion and is for sale, find more details using the button below
Garage / utilities
The rear of the van houses all the utilities. The electrical, water and gas systems are stored here.
We’ve chosen the Truma D4E as our hot water / heating source. It’s an incredibly versatile unit that runs directly off the vehicles main diesel tank, so no awkward filling of auxiliary tanks at fuel stations and introducing diesel into your rolling home. Fumes are exhausted outside of the vehicle away from any windows. Air for combustion is drawn from outside too which means no risk of reducing the available oxygen inside the van. This includes the iNetX panel which gives you control over ventilation, heating and hot water. You can also pair your phone over Bluetooth using their app to control the unit. Heating ducts run hot air around the van.
The gas locker is secured to the vehicle chassis and incorporates its own gas drop out vent, the regulator is housed inside the locker which can accommodate up to 7kg gas bottles.
Water is pumped from the underslung 70l fresh water tank through a shurflo pump. It’s a quiet pump with 30psi of pressure and using the accumulator means it’s only active when it needs to be. Water is carried through John Guest pipe and fittings with isolation points added between all components to make maintenance super easy.
This webpage will be updated as the build progresses