The Conversion Process
Step One: Campervan Design
This is where the journey truly starts, sitting down with us we take the time to go over every element of the conversion. We will discuss the use case of the van for yourselves as all builds can vary and we truly try to cater for everyone.
Moving on we will talk about colours and the vision of the van, discussing the colour of the floor, furniture, upholstery and carpet colour as a starting point. Hopefully this is where you will start to get a sense of what the van will look like when it’s finished.
There are a lot of options and we are happy to give advice to help you get the right result. After having built 100’s of campervans we know what works and what doesn’t quite hit the mark.
Moving to the outside of the van we can discuss extras, from critical parts such as awnings, multi rails or a headlight upgrade to more cosmetic choices such as side bars or body kits.
Stage Two: Vehicle Preparation and Cut Out
Once the design process is complete, your build date will arrive, marking the start of your campervan conversion journey.
We begin with a comprehensive vehicle inspection, cataloging the condition of the body, trim, and conducting diagnostics. This ensures you can trust that your campervan will be returned in the same condition it arrived.
Next, we carefully remove and store the internal panels for later refitting. This is followed by precise measuring and marking for any necessary cutting and drilling required for the conversion.
To ensure durability and protection, all exposed metal edges are deburred and treated with primer, safeguarding them from the elements.
Stage Three: First Fix Electrics
At this stage, we start the initial wiring for your campervan conversion. Our team carefully runs the main wires throughout the vehicle.
We install connections for the leisure battery, solar system, and other essential components. All wires are sized according to current load and run length to prevent voltage drop issues.
Each wire is securely fastened to avoid future problems, such as wear from rubbing or movement. We also double-check the manufacturer’s specifications to ensure optimal performance and reliability for your campervan’s electrical system.
Stage Four: Pop Top Roof
We supply and fit elevating roofs from several brands including “Skyline” we are happy to make recommendations depending on use case and budget.
This is one of the biggest tasks undertaken as part of a conversion and is critical that it is done right the first time.
Using nothing but quality products from start to finish and making sure we hit the tolerances required can be a timely process but not one to rush.
Stage Five: Carpet Line and Insulate
Now the roof framework is in place we move on to the job of carpet lining and insulating the van. Carpet lining the campervan offers one of the biggest transformations as part of the process as we go from a metal finish to one which is soft and seamless offering a lot of noise dampening. Before we start the carpet lining process we give the internal surfaces a good clean and key up the surface with a scotch pad ensuring we have the best possible surface for the trim spray to adhere to.
Insulating the van is an important step as it allows the van to stay cooler in the summer and warmer in the winter, it also helps in reducing noise in the campervan both when sleeping and travelling.
Stage Six: Heater Installation
We now raise the van to install the heater which we generally only use externally mounted heaters which helps us optimise storage space inside the van for yourselves.
Whether it’s a diesel Planar/Ebespacher or a Propex Gas heater we can cater for you, installed to manufacturers guidelines ensuring a quality install every time.
While the van is up we take this time to install any extras such as suspension components or side bars.
Stage Seven: External Styling
At this point we look to install any of the external extras desired for campervan, this could include things such as wind out awnings giving more usable space when camping, wheel upgrades, body kits even headlight upgrades.
We only use either OEM or reputable aftermarket suppliers known for quality and great aftercare.
Stage Eight: Flooring and Reinstall Trims
Next up is the installation of our one piece floor which is CnC’ed for precision out of 12mm plywood, no screws are used in the installation, only suitable adhesives meaning no screwheads that might make themselves visible down the line.
Following the floor setting we move to installing the floor covering which could be a safety floor lino or a more decorative version depending on the design.
Headliner and trim panels are now reinstalled and this is when the van is truly looking to come together.
Stage Nine: Furniture Kit
Here at Custom Fit Campers we have access to the very best machines when it comes to woodwork from top of the line overhead and twin axis cnc machines to edgebanders and even a heated press which allows us to form our own lightweight boards if needed for a truly unique finish.
However what makes us shine is the breadth of experience in the woodworking staff delivering quality work with drive and passion with decades of experience in the team the final product is always outstanding.
The furniture kit is installed and we are very much nearing the end of the process.
Stage Ten: Second Fix Electrics
With the furniture kit being installed we can now go ahead and second fix of the electrics, this includes connecting lights, switches and control panels.
The electrical management system is installed and check and the smart B2B charger, solar controller is also connected.
Ensuring the all wiring is correctly sized for the current and run length to ensure no issues moving forward.
Stage Eleven: Finalising
Finishing the build we install the bed, upholstery and glass, we’re now looking at a complete campervan and the conversion process is all but finished.
Following up with a good deep clean we look to start our rigorous quality control checks to help ensure you have safe and stress free adventures.