Taking a Look Into The Future - How We Have To Make This DIY Camper Build Look Great!

When building anything all of the decisions are left up to you. But sometimes we can get a little lazy. A recent video that was put out by the YouTuber Wranglerstar, talked about a young kid and how the kid wrote into him to tell him how he didn't cut corners when cleaning snow from under a car.

This approach really shows us, that deep down we are always trying to get ahead and cut the corners so we can get to the next task.

But what does this have to do with the design of a camper I hear you say? Lots! It can be really easy for some bits of wood that are a 1 or 2mm out to be left by the side and forget about them. But when you come back in the future you are always glad that you took that little bit more time to deal with the issue.

Ever Worked on Auto Body?

During my limited experience with auto body work I noticed one thing. This one thing should be hung above the painting booth in a workshop and given as introductory notes for new comers:

It all comes through the paint!

Something that you may think looks about right and you decide to speed up the process and get painting. Well as soon as the paint has begun to dry, your heart can then begin to settle also as you know those lines you saw before you painted are still there!.

How do we get around these problems? They are generally quite simple, finer grade sandpaper (good old wet and dry sandpaper) and then progressively move to a finer grade as time processes until all the marks are gone. During this process, using a high build primer would be a great option, as they add an extra thick layer for you.

To Bring This Back To My Camper

The top half and bottom half of the camper are going to be separated the two lines of different colours that meet together. I had a little idea spark off and thought wouldn't it be great if I could get some of the table trim from Eddie Rocket's Diner tables. It was about 2 inches wide, and would make a great band around the van to separate the colours.

I've found some nice US suppliers who have a wide range, and some others sourcing from here in Europe. Hopefully we can get these in time (and chromed) for the deadline. It is the attention to all of these details however, that make it all come together and look the best.

Winterizing Your Camper - Some Thoughts On Keeping Your Camper Warm

When starting a camper project from the very beginning, the conditions that the camper will be used in need to be considered. In the US, the temperature can go from sweating hot, to bone chattering cold between seasons. Here in the west of Europe, things are a little different.

We quite often get a middle range of temperatures, things never get too hot, or really go too cold. So an approach to this needs to be taken during the construction process of the camper.

Typically campers here do not have very thick walls. The same can be said for most vans and campervans that are currently on the market today. They are usually created for the good seasons, as people rarely go out on holiday in the winter months. But some people do!

The insulation in the camper can then suddenly be inadequate and warm days suddenly come with really cold nights. Preventing this from happening needed a lot of thought.

At the moment, the walls in the camper are currently pegged at being about two inches thick. This will give plenty of space for a two inch thick insulation, or 50mm for us European people, to be added in.

One of the recent advents in the insulation world was creation of polyiso insulation, or "rigid foam" as it is often known.

Unlike polystyrene insulation (the white stuff) you would have seen used throughout the 80's and 90's, polyiso insulation is denser and often covered in a foil film offering better insulation. To ensure a good seal, a foil type tape is available to seal up the gaps.

Where Your Camper Loses Heat

People often wonder about campers and where all of the heat is really lost. It can be seen from a number of different angles. Below is a breakdown of where your heat goes!

1. The floor of an RV or a camper is often made from some wood or floor pan sheet metal that has been added to the chassis frame. In a lot of cases, that is really it! Although heat rises, a cold floor can quite quickly turn your hot air into cold cold air.
   
   By insulating the floor, we can reduce the risk of losing heat out of the floor. The wind gap underneath the camper or RV is also an issue. Because the floor is raised up and a gap of anywhere between 10-14 inches is there, cold air can easily flow in under the camper. To prevent this draught from happening, people have often moved towards the idea of creating a skirt around the camper. This can stop the flow of cold air under the camper.
2. The roof of the camper again, like the walls needs to be insulated. If all the hot air is hitting your roof, you need to ensure that it is not a cold metal surface that can turn your expensive hot air into cold air.
3. Windows and doors although useful during the day if left open at night can becoming gaping air holes allowing all your precious hot air to flow out. Do not block up your vents however, they are needed for safety!

Heater Strips
If you have external water sources, one product that is on the market are heater strips designed to go around your pipes. They require a very low voltage and keep your pipes just above freezing to keep the water flowing, preventing cracks and leaks.

This solution however, can be costly to power if you are running on a solar rig.



In conclusion, as soon as the camper outside plywood has been added, it is insulation time!


A nice comparison of insulations can be found here
For a little bit more about polyiso insulation, check out here

The Walls Were Added To The Camper - And The Rain Returned

Now that the floor was added the most interesting part was about to start. The walls create realistic dividing lines in the camper and allow you to see what the space is really going to look like. Seeing it all down on paper is always just one perspective, really being able to climb inside is always the most valuable.

To get started, 2x3 inch wood was added to the four corner posts. Simple L brackets were used, with some three inch long screws to secure them in place. These, are pretty shaky by themselves so the next important part was to add the securing braces between them. The wood running between them was 2x2 inch timber when secured in place with some L brackets really pulled it all together.

The picture below shows a look from the inside:

The rain, once again started off so there was a really quick rush to get the tarp on top once again. All the rope and bungee chords that could be found were used to secure all of the eyelet holes on the tarp in place. The rain is always a small percentage of the problem, the wind is usually is what pulls the tarp off.

Looking in from the very front of the camper, the size really becomes visible. Some temporary diagonal pieces were added to hold the frame in place for the week, before it could be fully secured. The beautiful red anti-rust paint can be seen a mile away on the trailer. It sort of adds a kind of character to the trailer already... sort of.

This rectangle frame, was 3ft 6inches tall, and runs the whole way around the camper. This is the dividing line between the bottom half of the camper and the top half of the camper, which has a tilted in design as can be seen on the VW campers. Now that the frame is in place, the next step will be adding additional strengthening pieces to make sure the all of the walls stay put.

To the very front left of the camper, a space about 2 foot wide is where the door will eventually be placed.

The Tools For Building The Camper

Before any project begins, it is always a good practice to see what tools you are working with to make sure that you don't go running out looking for things when you really need them. So far my favourite tool has always been the angle grinder, as it is a single solution for any metal related problems that happen along the way. 

Apart from this, the usual tape measure, hand saw and plenty of screws are all that have been used oh, and a circular table saw!

Although technology has evolved and the process of using electrical saws has been around for years, this was the first project where I actually used one. Due to the amount of cuts that were needed, the idea of the electrical saw just seemed better. This actually speeded the process of erecting the frames so much quicker, although the saws are 100% more dangerous than anything you operate with your own power like a hand saw as they can quickly take your fingers off.

So far we have been lucky and no injuries have been sustained.

Where Do We Start? Self Build / Self Built DIY Camper Trailer - The Journey So Far.

Building a DIY Campervan

Where do we begin?. It all started a number of years ago, the idea of getting a camper van and getting onto the road and seeing what the world had to offer. Quite quickly, anyone with a limited budget will see that the idea of getting hold of a camper is not that easy of a feat!

Everyone wants a 79 westfalia camper, they look great. The main problem with this is that they are very very old. With age, comes rust.. The idea of getting a camper is any great condition was going to be an investment of 5000 - 10000 euro easy, and who knows what the outcome would be.

As a solution to this, I moved towards the idea of buying a VW Transporter, 2004 to be exact. A long wheel base van would provide more than enough space to fit my bed into along with a host of other features that would be needed.

The idea of getting a van onto the road, for someone who doesn't really need a van causes one heck of an issue for insurance. In short they do not want to know about it. Different counties have different rules, but in short the point was clear. If you want a van on the road for non commercial purposes, it would have to be a campervan legally and tax had to be paid, 1005 euro to be exact.

Well then, I had to get this van into a campervan as soon as possible.

The rules of building a campervan, to keep the insurance people happy
A number of different regulations had to be adhered to for the van to be considered a campervan, the main of which were:

• Vent holes in the side of the van to allow any stray gas get outside
• Copper pipes going up to a gas cooker, not rubber
• A guard around the cooker, to stop the back of the seats from melting
• A bed that pops out of the walls somehow
• No tables that can fly around the place. Everything had to be perfectly mounted and not become a hazard in the event of a crash.

All sounded perfect, and generally went to plan. A colour scheme was picked and the painter went ahead and painted the van. A window was cut into the side of the van and everything looked perfect.

And then:

• The turbo for the TDI engine broke
• Bits flew into the engine
• The engine exploded, sending a 40 foot wall of smoke shooting down the road
• Oil was everywhere
• Vicky the van, was dead.

RIP Vicky 2011-2013

After two short years, about 5 camping trips and more time on blocks and in a garage than previously expected, it all lead to the simple conclusion that the van needed to be sold.

On the back of this, a new project needed to be undertaken. This is the short version at least. And so, the future dream of a camper was put on hold until a new plan would come together.

Engines, were out. Trailers were in. 

The cost of running a campervan as much as I loved them, were a little too much. The part about enjoying the camper beside the beach or at a lake side was long gone after a number of deadlines were missed and the idea of going to France was just a botched plan.

In light of this, a trailer was purchased with the idea of building a DIY camper trailer. A trailer as in a metal frame with two axels in very very poor condition, with the idea of building a caravan, (or camper trailer or whichever the term is for campers without an engine in the US).


This blog will cover the project to date so far, showing, from the ground up, all of the steps that were taken. All hurdles will be described as they come into sight.

Until next time,
Kyle.