The Complete Van Conversion Guide
Every step of a van conversion in the correct order — with Australian gear recommendations at each stage.
🧱 Insulation
BeginnerThe first and most important step — insulation affects every season of van life. Do this right before anything else goes in.
💡 Tips
- →Thinsulate for walls, rigid foam for floor and ceiling
- →Cover all metal thermal bridges
- →Wool batts in roof cavities
🪵 Flooring
BeginnerLay your floor once the van is insulated. Choose something durable, waterproof, and easy to clean.
💡 Tips
- →12mm ply subfloor over insulation
- →Vinyl plank or bamboo finish
- →Seal all edges to prevent moisture ingress
⚡ Electrical & Solar
IntermediatePlan and rough-in your electrical system early — cable runs are much harder once walls are in. Size your system for your actual needs.
💡 Tips
- →Use our solar quiz to size your system
- →Run cables before wall lining
- →Always fuse within 300mm of the battery
- →Consider a DC-DC charger for alternator charging
💧 Water System
IntermediatePlan your water tank location before building furniture — tanks are heavy and need proper support. Run pipes alongside cable runs.
💡 Tips
- →Under-bed tanks are most space-efficient
- →Use 12V submersible or inline pump
- →Grey water tank or filter required in most states
🪵 Walls & Ceiling Lining
BeginnerClose up the walls and ceiling once electrical and plumbing rough-in is complete. Ply lining is the most popular choice.
💡 Tips
- →3–6mm ply for walls, 6mm for ceiling
- →Prime and paint or use vinyl wrap
- →Round all corners for a professional finish
🛏️ Bed & Sleeping
BeginnerDesign your bed platform carefully — it's the biggest space commitment in the van. Fixed vs convertible is the most important decision.
💡 Tips
- →Fixed bed is more comfortable
- →Measure your door opening for mattress delivery
- →Leave storage underneath — it's valuable space
🍳 Kitchen
IntermediateBuild your kitchen around your cooking style. Gas is cheapest; induction needs serious electrical planning. Allow bench space for food prep.
💡 Tips
- →Allow 600mm of bench space minimum
- →Sink drain needs grey water storage or filter
- →Gas needs proper ventilation and 12V solenoid cut-off
📦 Storage & Furniture
IntermediateFit out the remaining space with smart storage. Every centimetre counts in a van — design everything with dual purpose in mind.
💡 Tips
- →Pre-made cabinet carcasses save time
- →Soft-close hardware is worth the extra cost
- →Build a 3D model first — mistakes are expensive
🚐 Roof & Exterior
IntermediateRoof vents, solar mounts and roof racks go on last. Core-drill carefully — roof penetrations need proper flashing.
💡 Tips
- →MaxxAir or Maxxair fan for ventilation
- →Rhino-Rack or Thule for roof racks
- →Use Sikaflex for all roof penetration sealing
🌡️ Heating & Cooling
IntermediateDiesel heaters mount under the van or inside a cabinet. Roof fans are essential for summer. Install at this stage to route fuel lines and exhausts correctly.
💡 Tips
- →Diesel heater fuel taps off main tank
- →Run exhaust away from doors and windows
- →Fan + open window is the best summer sleeping setup
Plan your build budget
Use our interactive calculator to estimate your total build cost.