“Everything you need to know about converting a panel van into a campervan in the UK — from choosing a van to the final sponge hangin'.
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Table of Contents
- Step 1: Choosing Your Van
- Step 2: Measuring and Planning Your Layout
- Step 3: Insulation (The Most Important Step)
- Step 4: Flooring
- Step 5: Framing and Woodwork
- Step 6: Electrics
- Step 7: Heating
- Step 8: Water System
- Step 9: Kitchen Unit
- Step 10: Bed Platform
- Step 11: Windows and Vents
- Step 12: Finishing Touches
- Total Cost Breakdown
- Common Mistakes
Step 1: Choosing Your Van
For a UK DIY conversion, the sweet spot is a Ford Transit Custom or Fiat Ducato. Both offer the best value, parts availability, and are the most common platforms for UK van life.
Key measurements to note before buying:
- Internal width: ~1.5m (Transit Custom) or ~1.7m (Ducato)
- Internal height: ~1.3m (standard) or ~1.75m (high-top)
- Wheel arch dimensions: Critical for bed/kitchen planning
👉 Full van comparison: Best campervan for conversion UK
Step 2: Measuring and Planning Your Layout
The three standard layouts:
- Rear kitchen — best for families, keeps cooking mess away from bed
- Side kitchen — more space-efficient, classic campervan feel
- Bed-first — maximum living space, less kitchen real estate
Pro tip: Draw your layout on graph paper (1 square = 10cm) before buying a single material. This saved us £400 in wasted plywood.
Step 3: Insulation
This is where most DIYers cut corners. Don't. The UK gets cold, wet, and windy — and your van needs to handle it.
Our recommended insulation sandwich:
- Alfoil backing (underneath) — reflects heat back in
- Jazz board / PIR board (20-30mm) — main insulation layer
- Alfoil facing (on top) — moisture barrier
Material costs:
- Jazz board (24 sheets): ~£120
- Alfoil (2 rolls): ~£20
- Spray adhesive (4 cans): ~£20
- Total: ~£160
Where NOT to insulate:
- Around the engine (heat dissipation)
- Near the DPF (if your van has one)
- Inside wheel arches (you'll hear every stone)
👉 See our insulation deep-dive guide
Step 4: Flooring
Our approach: 18mm marine plywood + rubber floor covering.
- Remove factory carpet (it's held on with sticky tape — a fight)
- Lay 18mm marine ply (3 sheets per Transit Custom)
- Drill through factory floor holes for cable runs
- Cover with rubber floor (Sherpa or similar)
- Cost: ~£350
Step 5: Framing and Woodwork
Framing materials:
- Spruce battens (25x50mm): 12 bars ~£40
- plywood sheets (18mm): 4 sheets ~£80
- Screws, wood glue, corner brackets: ~£30
L-shaped skirting along the sides is the most practical approach. It hides wiring, provides storage access, and keeps everything structurally rigid.
Step 6: Electrics
The essential 12V system:
- Battery: Battle Born 100Ah LiFePO4 (£800) or similar
- Inverter: 300W pure sine (£150)
- Solar: 2x 100W panels (£200) with PWM controller (£80)
- Wiring kit: £30
- LED lights: £50
Wiring order:
- Battery → DC fuse → isolator switch → bus bar
- Bus bar → individual circuits (LEDs, fridge, 12V sockets)
- Inverter → 30A MCB → AC sockets
- Solar charge controller → battery
Pro tip: Use a multimeter to test every connection before closing everything up. The smell of burning wire in a closed van is distinctive.
👉 Full guide: Best campervan battery UK
Step 7: Heating
5kW diesel heater (Amazon UK standard kit): £150-£250
This includes:
- Heater unit
- Exhaust pipe
- Fuel line from fuel tank
- Thermostat
Installation: Mount on the side wall (not the roof — less vibration noise). Connect to fuel line and exhaust. Run thermostat wire to a wall mount near the bed.
Performance: Heats a Transit Custom from 0°C to 20°C in about 15 minutes. Fuel consumption: 0.2-0.4L/hour.
👉 Our full review: Best diesel heater UK
Step 8: Water System
The simple UK solution:
- 20L freshwater tank (plastic, with tap)
- Hand pump or electric pump (£15-£40)
- Sink ( IKEA Bitsuban or similar: £30)
- Copper pipework
- Hosepipe for filling
No plumbing needed — everything is self-contained. The key is having a hosepipe and a sink in the kitchen unit.
Step 9: Kitchen Unit
Build from plywood or IKEA Alex drawer units (your choice). Our kitchen includes:
- Double burner gas stove (Coleman or similar)
- Sink with drainer
- 10L fridge/freezer (Dometic or Thetford)
- Storage drawers underneath
Cost: ~£500 for all components.
Step 10: Bed Platform
Optimistic dimensions for a Transit Custom:
- Width: 1.2-1.4m
- Length: 1.8-2.0m (depending on kitchen position)
Build from plywood with 50mm foam mattress on top. Add slats underneath for storage.
Step 11: Windows and Vents
Windows: Team Trading is the UK standard. Square portlights are easier to install than rectangular. Budget 3-4 windows for good cross-ventilation.
Vents: Make-Shift Max Fan is worth every penny for UK weather — its weatherproof design means it won't leak when it's raining sideways.
Step 12: Finishing Touches
- Curtains: Buy standard Amazon curtains (not van-specific) — much cheaper
- LED lighting: USB-powered LED strips along the ceiling
- Hooks and baskets: For everything
- Magnetic bug screens: Essential for UK summer
Total Cost Breakdown
| Item | Budget | Realistic |
|---|---|---|
| Van | £15,000 | £22,000 |
| Insulation | £160 | £250 |
| Flooring | £200 | £350 |
| Woodwork | £150 | £300 |
| Electrics | £800 | £1,500 |
| Heating | £150 | £300 |
| Water | £80 | £150 |
| Kitchen | £300 | £500 |
| Windows | £200 | £400 |
| Mattress | £150 | £300 |
| Finishing | £100 | £300 |
| Total | £17,290 | £25,750 |
This guide is updated regularly. Questions? Contact us. We're happy to help fellow DIYers.
