This project came about earlier this year as a result of a young couple with 3 children who asked me to help them to realise their dream of owning a camper. They had previously researched the idea of converting a van themselves and had already purchased a 52 reg Ex Police Mercedes Sprinter which had been used as a camera van in its former life. This was the LWB twin wheel 5.5 ton version.

They also had a good idea of the layout they wanted but needed help in the final design and the execution of the difficult parts of the build. It was agreed that I would commit 15 days of work and that they would carry out the final finishing jobs. The van was already equiped with windows, Internal panelling, Diesel heater, Air con unit, and minibus seats with integral seatbelts. The owners believed that as it was already lined and had windows it was almost a campervan  ( indeed it was advertised as that ) and that it would not take too much  work to make the required modifications to turn it into the van of their dreams. They had already treated it to a complete re-spray and employed an auto electrician to re- commision the eberspacher heater and the Air conditioning unit fitted above the cab.

It soon became apparent that  Ex police vans are not the best choice for a camper conversion. Firstly, they have steel re-inforcement beams running the length of the sides and the roof making it very difficult to cut holes for vents and rooflights. They are not particularly well insulated, but at least they have some. They are lined with 5mm thick Makrolon which is an almost indestructable Polycarbonate sheet which is designed to withstand explosions and pick axe attacks. The windows are polycarbonate and vibrate as you drive along. The floor is almost 3" thick with about 4 separate layers of plywood. Everything is rivetted  in place and there is a maize of useless wiring throughout the van which was originally connected to untold ariels and flashing lamps and camera equipment. The advantages of being an ex police van is that it was in reasonable condition, It had a good service history and relatively low mileage on a 5 cyl 2.9 Ltr powerful engine. so , at least , it should be reliable and fun to drive.

The Makrolon lined interior before the conversion was started.

Cutting holes proved to be a challenge. It had to be done with an oscillating saw.  Note the steel reinforcement bars and the Location of the Diesel heater. That was left where it was but the outlet ducted out though a vent in the under seat locker.

What the hole saw had to deal with to make holes in the floor.!

The roof lining  and the steel beams removed and the 3 rooflights in place.

The plan was to have a dinette arrangement with seating and a table at the front of the van, a raised bed for the children at the rear  with a large storage space underneath and a split kitchen with the cooker on one side and the sink and fridge on the other. The adult bed was to be made up from a pole support system strung over the top of the backs of the minibus seats and located in the headrest mounting holes with a folding ply board laid over it.

Decisions were made not to include a water heater, Oven, or a permanent toilet. An underslung water tank for fresh water was to be fitted but no waste tank. Much of the equipment was obtained secondhand through Ebay and orders were placed for the timber materials and all the electrics and plumbing requirements through local suppliers and Leisureshop direct .

The first job was to cut out the holes for the fridge vents, the 240v inlet, the water filler and the 3 roof lights The Makrolon lining was removed from the ceiling to expose the reinforcement beams. these were ground away and removed . the floor had front to back rails to secure the seats but these protuded above the floor so before a level floor could be laid I had to lay a spacer layer between the rails and then a ply floor was laid over that.

The fridge vents and 240v hook up and water filler fitted

The floor under layer and ply being laid. I used fibreboard type laminate underlay and 9mm ply over that.

The minibus seats were then re-positioned and secured. these all had integral seat belts so this van now had 7 belted travelling seats.

The next task was to run all the cabling for the electrics though convoluted ducting fed behind the plastic lining. not an easy job. Then the water tank was positioned on the off side just behind the drivers seat. This was made difficult by the fact that the fixing for the seat rails protruded under the floor and this reduced the clearance for the tank. So the fixings had to be removed and relocated which caused a few hours extra work. The Shurflo  water pump was located in the unit under the sink. the gas bottles were sited at the rear in a locker under the hanging space with access thought the garage space. I used 4.5Kg calor bottles as it was thought that the van would be used mainly in the UK.

The rear bed with the hanging locker and the gas locker underneath

The seats being boxed in after the floor was laid

I  ,then, pressed on  to build the furniture units and fit the appliances. 2 x110AH batteries were fitted under the dual passenger seat locker.  and all the electrics were chanelled to the bulkhead at the front where the 12v & 240 v distribution unit was located.

the ceiling was panelled in and over head lockers were constructed incorporating 2 speakers which were connected to a very up market kenwood audio system fitted in the cab.

Fridge in place

Battery box before the new batteries were fitted.

Looking forward, The birch ply cladding in progress . Note the removeable support bars for the rear bed  . With these removed and the bed base folded up the van could be used to carry bulky items or adult bikes when needed.

The construction of the furniture and the lockers was made from 20x32mm planed softwood glued and nailed as a framework and then clad in 3mm birch ply. The worktops were 28mm thick standard beechblock worktops bullnose rounded on the edge. the bed and the structural bulkheads were made from 12mm hardwood ply.

Looking Aft. The rear bed in place and the work tops fitted.

The cooker side of the kitchen

The sink & fridge side of the kitchen

The locker doors, painted and fitted.

The under-seat lockers and the table

The adult bed was made up form 25mm square tube with spigots fitted to insert into the location holes of the headrests. Then cross members were fitted over these poles and 12mm ply boards fitted over that. roll up foam mattresses were then placed over that. The poles were stored in a purpose built shelf above the table area. The doors and the table were made from 15mm MDF with the edges rounded off and finely sanded before sealing and painting.

Looking forward with the storage locker now finished.

The Boot! Plenty of room to stash a lot of gear. Note the access door to the boot from the living space. This was to access bedding and the porta potti , which were to be stored there, without having to get out of the van.

The Family Camper- Finally finished and being enjoyed.