Campervan conversions: Vauxhall Movano self-build

Setting out our requirements

The idea was to create a comfy five berth off-grid camper that was small enough for our weekend bike trips around the Peak District, but big enough for a long stay. The most important aspect was that it would have to be self-sufficient for off-grid living during our weekend excursions to the Peaks.

Choosing the layout

We travelled round various motorhome retailers looking for inspiration but soon came to the conclusion that, to use a van of this size for five people, the layout was going to have to be bespoke and would require a lot of thinking outside the box.

Mechanical repairs first

The first job was to address the engine cutting out – after all, there was no point investing time and money converting the inside if it was going to be unreliable. I soon pin- pointed the fault to a weak pressure limiting valve on the common rail for the injectors, which I managed to source locally from a diesel specialist for less than £80.

Collecting all the parts

After running the van to work and back for a month or so with no cutting out issues, we decided it was time to get on with the conversion. I spent the next few weeks collecting all the parts I thought I needed for it, and making sure the van was mechanically sound in all aspects.

The conversion work begins

A target set: The ferry is booked

After stripping the van bare we decided what better motivation to get the job done than to book a holiday in Europe! That night, we booked the ferry and a campsite in Switzerland – the countdown really was on now.

Sound proofing and an issue to solve

With the holiday booked, it was time to get the project moving. The first job was to apply the sound deadening to all the panels of the van, which soon highlighted another problem. When working in the back of the van for a day, I soon realised that the standard high-top was not going to be quite high enough for me at just over 6ft 4in to have a comfortable holiday!

At this point, most people would consider a different van or pop-top but we had other ideas… Why not remove the extra high top from a scrap van and fit it to ours? 48 hours later we had managed to get one from a scrapyard in Birmingham and have it fitted to our van – and what a difference the room made!

Electrics, insulation and vapour barriers

Now happy with the space inside, we carried on with installing the electrics, insulation and vapour barriers. It was a great feeling using the van as a daily driver and noticing the difference every week as it evolved from a cold rattily panel van to a warm and silent ride.

Carpentry skills to the test

After several weeks, the basics of the van were complete: electrics, insulation, windows, skylight and the basic layout of the van had now come together, and it was time to put my carpentry skills to the test and start on the woodwork. We took a ride out to Magnum Motorhomes at Grimsby and purchased everything for the final fix then, that weekend, we built all the cupboards and rear bunks. The van was now really being transforming into a campervan and the end was in sight. That Sunday night was spent in the van, on the drive, as the kids couldn’t wait any longer to try out the new bunks! It was an insight for us to see what an improvement this was going to be over the tent.

fine-tuning and trimming

The next few weeks were spent fine-tuning and trimming all the cabinets, and addressing any little squeaks and rattles I noticed on my daily commute to work. Now happy with the cabinets, it was time to fit the appliances. In went the oven, fridge, sink, hot running water and night heater. It really was starting to feel plush and we were extremely proud of our first family effort at building our own campervan from scratch.

Fitting the beds

The last job was to come up with somewhere for me and my wife, Debi, to sleep, as the usual layout of having the bed widthways across the back of the van simply wasn’t long enough for me to have a good night’s sleep. In the end, we managed to fabricate our own swivel bases for the front seats and custom-make the dinette seating to allow it to come together to form a king size bed, all topped with 100mm foam – this is super-comfy! The final job was to re-trim all the seats, which we matched throughout, including the kids' mattresses.

So did we make the ferry?

Yes, but only just!

Self-build: what we learned

#1. So satisfying: we made every part

The best thing about the camper has got to be the fact that we made every part ourselves, allowing us to utilise all the available space. There’s nothing more satisfying than sitting in the 'van and noticing all the little bits the children have helped with or the things that have caused a headache along the way.

#2. It has transformed our travels

Since completing the campervan, it has transformed what we can do, from taking the kids out on a snowy day in the Peak District knowing we have a warm retreat waiting for us, to three week treks across Europe every summer, and random weekends away all across Britain.

#3. We love the versatility

We love the versatility of the 'van – it’s unique and it’s tailored exactly for what we want, which you simply couldn’t get by buying one off the shelf. We like the fact that you can reach places and stay over for the night that you would normally miss by flying to your holiday destination. The 'van allows you to make the journey part of your holiday and simply stop off wherever you fancy.

Issues and future plans

• Storage

So have we had any issues? Yes, a few small ones – every time we use the 'van we always come up with something to change! We are finally happy with the internal layout and storage but, for longer trips, a little more external storage would be great. So we plan to build a custom roof rack for those extra bulky none-essential items and mount an underslung waste water tank.

• Grip on grass

Another small issue we found during a visit to Bakewell on a very wet day was that the 'van soon gets stuck on the grass! As the Peak District is a regular destination for us and we’re normally travelling solo with the bikes, we’ve opted to order a set of all-terrain tyres to gain that extra bit of traction. Internally, the only small tweak is going to be to raise the dining area floor to be level with the cab floor, as this will also add additional storage, making use of dead space.

• A better towbar

The biggest challenge is going to be to fabricate a swivel tow bar for the bikes. Having three children, the only option we have is to use a towball mounted rack, which is a brilliant bike rack. However, on a van with barn doors, accessibility is then impossible, so the idea is to make a swivel arm mounted to the original towbar. A simple pin that can easily be removed will allow access to the rear doors in a flash!

• It’s become part of our family!

So would we trade the campervan? Not a chance! It’s become part of the family now. It fulfils everything we need. It’s true that large motorhomes are great for space but our 'van, with minimal overhang, allows us to travel down roads and tracks that large motorhomes would struggle with. We’ve got a five-berth campervan with all the comforts of a mobile home, but we’re still small enough to tuck into a small layby for the night.

Campervan conversion details

• Base vehicle: 2006 Vauxhall Movano panel van
• Conversion type: hand-built self-conversion
• Owned since: 2014
• Drive: front-wheel drive
• Engine: 2.5 CDTi Turbo-diesel
• Power: 120bhp
• Economy: 39mpg
• Gearbox: 5-speed manual
• Travel seats: 5
• Berths: 5
• Leisure Battery: Twin 120 Ah
• Payload: 650kg
• Length x Width X Height: 5.9m x 2.0m x 2.7m

Best trip so far

"I think the most memorable trip to date has got to be our two-week stay at Jungfrau camping in Switzerland – opening the side door to the view of the snow-capped Eiger, Mönch with a coffee in one hand and a local pastry in the other takes some beating!"

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