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A Hyundai van converted into a campervan with double sofa bed and loads of built-in storage in just five weeks using Bunnings materials.
The project
I've always wanted to do a van-to-campervan conversion. My son rang me up and said: "Dad, I've just bought myself a van and l was wondering if you'd like to have a crack at converting it into a camper?" I think he knew l’d jump at the suggestion. Five solid weeks later a campervan was born!
My son bought himself a 2015 Hyundai iLoad for $15,000 with nothing but bare bones, so we had to start from scratch.
The "brief" was scant but precise:
- It had to have room for him to sleep and sit comfortably
- There needed to be a safe spot to securely store a surfboard or two overnight
- There's not a lot of coin to do all this so the budget is tight... so nothing too fancy!
Living in rural NSW meant that l didn't have a lot of options regarding sourcing materials for converting a van but luckily we do have a Bunnings so they saved the day. Basically everything for the van was purchased from Bunnings except for electrical components and soundproofing.
Here are a few of photos of the finished project.
The LED lights are one of the features of the van which helps to highlight the slatted ceiling.
Plenty of storage in the wall cabinet and the natural holes in the vans side panel make a convenient place to hang some clothes hangers.
Two toned cabinetry makes the decor pop.
Surfboard storage under the bed stores the boards safely while you sleep overnight.
Plenty of storage with a one metre pull out drawer and the sofa bed is very comfortable with a two-piece foam mattress.
The rattan door on the electrical box ensures plenty of ventilation for the electrics whilst the extra drawer provides another handy storage compartment.
I'm a big fan of Four Way Stretch Carpet. Just stick it to some MDF for a luxurious finish.
The VJ was a little difficult to install due to the uneven and curved face of the wall and door panels. A little force was required to secure it in place and just make sure that you screw to a panel that is not the outside skin of the van. Check twice, screw once. The black button head screws are nice accent against the white MDF.
The white plywood legs are cut out of the one piece of material - no joints!
I'm 6'2" and can sleep comfortably with legs outstretched.
Handy pull-out kitchen with open storage underneath.
The 30-litre fridge is a great option.
If you don't surf you could use this space for extra storage.
Three styles of charging ports:
- Two USB ports
- One USB port and one USB-C port
- One automobile auxiliary power outlet.
The wall mounted fan is a necessity for a comfortable van life.
The LED strips are a simple way to create a stunning look.
The vinyl plank flooring looks great and is simple to install.
The pull out sofa bed is a very effective way to kill two birds with the one stone.
The open storage is a great place to store your devices, clothing, books, etc.
I love the overall look of the conversion and combine that with truck loads of storage, you have yourself a very neat little package.
Gotta love a little greenery!
Step 2
A few of snaps of the job in progress! This is Jack, my 26 year old son who's van it is.
Floor battens glued down to the floor pan with insulation glued in between the battens.
Detailed plans.
Holding up the ceiling battens till the glue dried.
Timber slats nailed to a 3mm sheet of MDF that l painted black for accent.
Sound-deadening material was applied to the areas of the van that sounded 'tinny'. These tinny areas were on the wall and ceiling panels and also the wheel arches where road noise is transferred.
Insulating your van is an important step as they can get really hot in the summer and very cold in the winter.
The bed box is an integral part of the build as everything else is built around it.
Running the cabling for the lights, switches, fan, charging ports etc.
The plywood floor was installed in two pieces. There are so many ins-and-outs with a van that it would be very difficult to do it out of one sheet.
I'm a massive fan of the 17mm Formply. It looks awesome and is generally straight and flat.
The cabling was a little tricky to run back to the battery but we got there in the end.
The pull-out kitchen works well as a place to use and store your gas cooker.
The engine room for all the electrics is located under the bed.
A 100AH Lithium battery runs all the electrics which is charged from the vans battery as well as the solar panel on the roof.
The backrest is a game changer for the pull out bed. You can sit in the van comfortably without your head hitting the ceiling.
Having the fridge and electrical compartment accessible via the side door is very convenient.
Hear duty drawer slides work an absolute treat with the drawer. Having the drawer lockable prevents it from coming out when driving.
Project build videos
I created two videos that documented the building phase.
Here is a video where l reveal the van to my son.
Tools and materials
Materials used in the project:
- Black formply
- Foilboard insulation 10mm x 2400mm x 1200mm
- Untreated Pine 2.7m x 90mm x 35mm
- White primed Pine
- MDF 3mm x 2400mm x 1200mm
- Plywood 2400mm x 1200mm x 9mm
- Natural self adhesive vinyl floor planks
- Easy VJ MDF 2400mm x 1200mm x9mm
- Goliath 1000mm lockable drawer slides
- Goliath 600mm lockable drawer slides.
Tools used in the project:
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Afternoon @DIY4Knuckleheds
Oh man, now that is something I have had in mind myself! You have done a really nice job on it. Clean lines and functional plus you have sound deadening and insulation in there as well 
Definently something id be happy to have built!
Dave
