Why the HiAce Is Australia's Most Popular Van Conversion
The Toyota HiAce is the dominant van conversion platform in Australia — more HiAce conversions exist here than any other model, and for good reason. Parts are everywhere, mechanics know them intimately, resale is strong, and the long wheelbase model provides enough length for a comfortable permanent bed without losing storage.
But how much does it actually cost to convert one? Here's a realistic breakdown for a full-time liveable conversion in 2025 AUD prices.
The Van Itself: A$8,000–25,000
Your budget starts before you swing a hammer. A HiAce suitable for conversion:
- Budget (200,000km+, older model): A$8,000–12,000. Higher risk, lower entry cost. Buy with a full mechanical inspection.
- Mid-range (100,000–180,000km): A$14,000–20,000. Sweet spot for most converters.
- Low mileage/newer model: A$22,000–35,000+. More reliable, less conversion risk.
Insulation: A$400–900
Insulation is the most labour-intensive part of the build and one of the most impactful for comfort. Most builders use a combination of:
- Spray foam or Kilmat sound deadener on panels: A$100–200
- Thinsulate or sheep's wool for walls and ceiling: A$200–400
- Rigid foam board (Polyiso) for floor: A$80–150
Flooring: A$200–600
Most builds use 12mm plywood subfloor over rigid foam insulation, topped with vinyl plank flooring. Budget A$200–400 for materials. Luxury vinyl plank (Bunnings) looks excellent and handles the moisture and movement of a van environment well.
Bed Platform: A$300–800
A permanent fixed bed is the foundation of a functional van build. In a long-wheelbase HiAce, a fixed queen or double bed fits lengthwise along one side. Materials (structural ply, timber framing, hardware) typically cost A$300–600. Add A$200–400 for a quality van mattress — a 75mm cut-to-size foam mattress from Clark Rubber is the most common choice.
Electrical System: A$1,500–3,500
This is typically the most expensive component of a serious build:
- 200Ah LiFePO4 battery: A$800–1,200
- 200–300W solar panels: A$300–500
- MPPT charge controller (Victron): A$200–350
- DC-DC charger (REDARC): A$350–420
- Battery monitor, fuses, wiring, fuse block: A$300–500
Total electrical: A$1,950–2,970 for a quality system.
12V Fridge: A$700–1,100
The Waeco CFX40 (A$699–799) and Engel MT45 (A$990–1,099) are the two most common choices. The fridge is the highest-use appliance in the van and worth investing in.
Kitchen Setup: A$400–900
- 2-burner LPG camp stove (or built-in): A$80–300
- Cabinetry materials (ply, hardware): A$200–400
- Sink, hand pump or 12V pump: A$80–150
- Water tank (20–40L): A$60–120
Ventilation: A$300–450
A roof vent fan (Maxxair or Fan-Tastic) is essential for Australian summers. Budget A$300–380 for the fan, plus A$50–80 in installation materials.
Hot Water: A$280–350
The Joolca HOTTAP Evo is the most popular portable solution — A$289–320 and connects to a standard LPG bottle. No permanent installation required.
The Full Build Cost Summary
- Van purchase: A$14,000–20,000
- Insulation: A$600
- Flooring: A$400
- Bed platform + mattress: A$900
- Electrical system: A$2,500
- 12V fridge: A$900
- Kitchen: A$600
- Ventilation fan: A$380
- Hot water: A$300
- Miscellaneous (fixings, paint, finishing): A$500
Total build cost: A$21,580–27,080 (not including the van)
All-in with van: A$35,000–47,000 for a mid-range build
Where to Save and Where to Spend
Spend on: Electrical system (quality here prevents fires and headaches), 12V fridge (you use it every single day), and insulation (can't fix this later without a full tear-out).
Save on: Kitchen cabinetry (simple open shelving works), flooring (Bunnings vinyl plank is excellent), and decorative elements.