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.