Conversion Van

It’s not hard to understand why a person would view a conversion van and develop the desire to create one themselves. After all, cars are already considered an expression of one’s personality and a customized van would seem to be the ultimate form of vehicular expression. Add to that the convenience such a vehicle would offer to the outdoor enthusiast, the busy executive, the wealthy playboy or girl on the road, and a conversion van makes an appealing alternative to a regular car.

But while many of those people have the means to purchase a conversion van pre-assembled, or to have the features they desire installed at their request, many others might have to settle for doing it themselves. It’s not an impossible task, but it requires preparation, a basic knowledge of automobiles and the right tools.

The most important first step, of course, is selecting the right van for the conversion process. If you already own a van, you’re most likely have already made the decision on the vehicle you’re going to convert. But if you’re starting from scratch, you have two choices: purchase a new, but stripped-down van, or purchase a used van that you can tear down and rebuild to your own specifications.

Both choices require careful planning. Unlike authorized conversion van dealers, who received specially prepared van bodies from the major car manufacturers that are designed to be converted from the ground up, a pre-existing van, with many features already built in, may not be designed to handle the requirements of customization. For instance, putting in special features not originally designed to be added to the van, such as beds, stoves, sinks and bathroom facilities, will add additional weight to the vehicle and alter its center of gravity, thus affecting its handling while driving, You may need to make modifications to the body to compensate for this change.

In addition, this new weight load may put an unexpected strain on the existing engine and transmission, so you should consider the required power of both of these essential elements before adding new features.

Next, begin to design your conversion van in your head. What features do you want? What will be the primary use of the van (Business? Pleasure? Camping? Quick trips around town?) How many passengers do you expect to transport regularly? Do you expect many long trips or short trips? And, finally, how much are you willing to spend to convert it? All of these factors, and others, need to be considered before spending any money on parts or the van itself. Some vans may be less expensive but smaller in size, while others may be roomy but use considerable gas. Consider all of the options before making any purchase toward the project.

Now that you’ve decided on the van you want, its intended use and the dollar amount you’re willing to spend, assess your automotive experience and considering how much help you’re going to need. If you’re a weekend mechanic who’s familiar with an engine, that doesn’t necessarily mean that you understand the intricacies of a vehicle’s electrical system, its suspension system, the transmission, etc. It’s not unusual for an amateur mechanic to begin a massive project such as van conversions and quickly find they’re in over their head. Know your limitations and arrange for help from a knowledgeable friend or mechanic beforehand. In addition, there are many website bulletin boards devoted to van conversion where other van enthusiasts are more than willing to lend a hand.

With the list of items you’ll need handy, begin your search for the parts at your local automotive store or from online parts dealers. It may be tempting to scrimp, opting for the cheaper version of an essential part rather than pay a few dollars more, but this is a mistake. Do not compromise on parts and equipment that are important to the operation of the vehicle and, ultimately, your safety.

Depending on what features you plan on adding in you van, you may want to consider adjusting the suspension before installing them. Again, you will be adding weight to van that may have been originally designed to carry. Lifting the suspension and strengthening the load-bearing capabilities will ensure a smoother ride.

Purchasing an automotive manual designed for your vehicle’s particular make, model and year will provide you with a diagram of your car’s electrical system and its capacity. It may be necessary to add an additional battery to provide auxiliary power in case you plan on installing a few additional features (light, electric stove, etc.) that may drain power from the regular battery.

Finally, special tools may be needs to secure items like seating, sofa beds, tables, cabinets and shelves to the interior of the vehicle. Welding may be involved, as well as metal drills and special fasteners. Additionally, if you plan on installing windows in the van where there are none, a metal cutter is a must.

With all of the special features a modern conversion van contains, creating one is not a simple task.  Though many amateurs and a few private professionals have created some exceptional examples of conversion vans, the vast majority of the conversion vans on the market today are created by the major car companies themselves (featuring just a few modifications, such as captain’s chairs and perhaps a rear table) or by a few companies working closely with the major manufactures.

At the outset, vans slated for conversion are empty and devoid of accessories, even windows. They are usually half-ton or three-quarter ton cargo vans from Ford (E-Series), Chevrolet (Express or their GMC Savana) or Dodge (the Sprinter model). The Conversion Van Marketing Association, an eight—member group, is the only organization whose members are authorized to build conversion vans based on Chevrolet or GM models. Likewise, Midwest Automotive Designs, based in Elkhart, Indiana, is one of only a handful of companies authorized to create conversion vans from Sprinter models.

Dealers provide the authorized manufacturers of conversion vans with a basic, conventional cargo van on what is known as a cutaway van chassis. A cutaway van chassis usually consists of the van’s front end and cab only. The rest of the van’s body is incomplete and the back end is usually covered with cardboard or plywood until it reaches the conversion company.

First, the second stage manufacturer determines the purpose of the vehicle. It may be used for private transport or commercial purposes. But knowing the usage intended by the end consumer is important. Next, the overall design of the vehicle must be determined. The seating arrangement, lighting arrangement, electrical equipment arrangement must all be mapped out early in the process to ensure the correct configuration of the essential elements, such as the wiring and heating system. Also the design of the outer body must also be considered at this stage: the placement of windows, etc.

Next, the second stage manufacturer begins installing the base equipment: special electrical wiring, special heating and fuel elements and tanks, ducts for heat and toilet facilities (if included). Since these will be inserted into the body of the vehicle where access may be difficult later, it is important to make the correct installation of these vital elements now.

Now the body of the conversion van may be attached. Remember, the van has been sent to the second stage manufacturer with only the front cab area intact, so care must be taken to assemble the back section to the front as seamlessly as possible. Because of the prior planning, the electrical wiring system and other vital systems should fit perfectly and mesh with the newly installed outer body.

Once the outer shell is in place, the windows may be installed. Adding special windows in a conversion van adds natural light and ventilation and is important if the user wants to take advantage of the sunshine while camping. While windows are a welcome feature to most users, they also reduce the security of the vehicle, which must be taken into consideration. Among the type of windows that can be added are bonded windows (factory fitted windows which are flush to the body and usually attached with an extremely adhesive strip), rubber mounted windows (a glass window that sits in a large rubber frame in the window hole of a van), caravan windows (windows in which an outer part is attached to an inner part and held together by a bolt that goes through the wall of the van) and a Seitz window (a complete product which includes a window, screen and blinds in one unit that is fitted by an inner frame).

Also at this stage, a sliding door may be added if the conversion van being worked on is a campervan.

Next, since the wiring has already been put in place, the lights and (if necessary) electrical outlets can be installed. Connections for sounds systems, televisions, satellite receivers and wireless connectivity can also be put in place to make installation of these features quick and easy. A second stage manufacturer may install a plate with electrical connectors just in case the owner decides to upgrade the equipment and doesn’t want to install all new wiring. As with a stereo or computer system in the home, it may merely be a matter of unplugging the old equipment and installing the new one.

Finally, the interior features may be installed: seats, counters, bars, flat screen TV sets, etc. These are securely affixed to the vehicle to ensure stability during travel.  In the case of a campervan, the sofa beds will be inserted to ensure they work properly within the space allowed, and in the case of an office conversion van, a desk may be installed and a work chair added and secured in place.