The First Challenges - The Battle Begins

After long sleepless nights making research and trying to find out answers to the questions(and hundreds of other questions) below:

• How to insulate the van?
• Should I use plastic to create a vapor barrier?
• Need to build as light as possible, since starting weight was already 2 600 kg.
• Using batten in the walls and roof or not?

I can tell you that we made multiple mistakes that I regret afterward, but what can we do if poop is already in our pants and don't want to start all over again.

Insulation

When it comes to insulation, the goal is to keep the van warm in the winter and cool in the summer. There are several options available, but we chose to use a combination of NMC Insul Roll XT from Amazon DE, Finnfoam plates from a local hardware store, and Ewona wool from some online shop. The NMC Insul Roll XT is a closed-cell foam that's similar to the commonly mentioned Armaflex insulation but more budget-friendly. The Finnfoam plates were added on top of the NMC Insul Roll XT, and Ewona wool was used in areas where the Finnfoam couldn't be applied.

Vapor Barrier

This started making me crazy while reading about a vapor barrier. Many posts and videos I saw were self-learned Bob the builders were talking about how important a vapor barrier is. Well, I'm not professional either, but I'm not going to start adding plastics or aluminum foil to create a vapor barrier. We believe that proper ventilation is essential for ensuring any moisture that does enter the van will be able to escape, thus avoiding the risk of mold or other moisture-related issues.

Weight

Weight is a major consideration when converting a van, especially if you're starting with a heavier van like we did. Our van had a starting weight of 2,600 kg and we wanted to keep things as light as possible. To achieve this, we used 4mm plywood for the interior and walls, and 22mm x 50mm wood for the structure. It may not have been the best choice, but it was a light one.

Battens or Adhesive

Finally, we faced the decision of whether to use battens or an adhesive for the walls and roof. After speaking with someone who had built several vans since the 1960s, we decided to use a 2-component polyurethane adhesive, Kiilto Kestopur PL 240. Unfortunately, this was a mistake. The adhesive was difficult to use and expensive, and we learned that it's always important to consider the advice of others, but also to make informed decisions for your own project.

 In conclusion, converting a van into a livable space requires careful planning and decision-making. By addressing the challenges of insulation, weight, and wall and roof finishing, you can turn your van into a cozy and functional home on wheels. We hope our lessons learned will help you make informed choices for your own van conversion journey.