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.