Finding the Van

The search took three months. Dozens of viewings, several near-misses, and one genuinely alarming example that looked fine in photos but had a floor you could push your finger through. Then, on a grey Tuesday morning in Shropshire, the right van appeared: a 2001 T4 2.5 TDI panel van in blue with 187,000 miles on the clock, a folder of service history, and rust that was present but honest — surface bubbling on the rear arches and one sill that needed attention, nothing structural.

The price was fair. The cambelt had been done at 160,000 miles. It drove cleanly, with none of the smoking or hesitation that spells trouble on a TDI. The decision was made on the drive home.

The Brief: What Kind of Van?

Before touching a tool, the goal had to be defined. This wasn't going to be a stylish Instagram van with shiplap walls and fairy lights. The brief was practical: a self-sufficient overlanding base capable of sleeping two, cooking real food, running from solar for at least a week off-grid, and handling rough tracks without drama.

That shaped every decision that followed.

Phase 1: The Bodywork

Three weekends were spent on rust before anything else happened. The rear arches were cut back to solid metal, treated, patched, and re-sealed. The sill was repaired by a local bodyshop — a cost worth paying for a professional finish on a structural area. Everything was treated with cavity wax before the van was put back on the road.

Lesson learned: Don't underestimate bodywork time. It always takes longer than planned, and it's easier to be thorough now than regret it when it's hidden under a conversion.

Phase 2: Mechanical Sorting

The cambelt was overdue for a second replacement and was done immediately — belt, tensioner, idler, water pump, and coolant all in one go. New front brake discs and pads followed. A new thermostat cured a slow warm-up issue. The gearbox synchros were already worn on 2nd (a very common T4 trait) but the cost to repair wasn't justified given how liveable it was.

Total mechanical spend before conversion: approximately £650.

Phase 3: Insulation and Lining

The insulation approach was a hybrid: acoustic deadening mat on the main floor and side panels, 50mm PIR board on the walls and roof where space allowed, and sheep's wool stuffed into every cavity and awkward void. The floor got 25mm PIR under a 12mm ply base.

The walls were lined with 6mm ply, painted in a charcoal grey. Simple, durable, and easy to wipe down.

Lesson learned: Spend more time on the insulation than you think you need to. Getting it right is slow, careful work. Gaps matter.

Phase 4: The Layout

A fixed rear bed was the non-negotiable. A rock-and-roll bed was considered and rejected — the extra faff of converting it every night wasn't worth the modest gain in daytime space. The bed runs lengthways on the driver's side, with storage underneath and a narrow corridor alongside it.

A simple kitchen unit runs across the rear doors: a two-burner propane hob, a small sink with a hand-pump tap fed from an under-seat fresh water tank, and enough drawer and cupboard space for basics. No fridge — a quality 12V coolbox pulls double duty and uses less power.

Phase 5: Electrics

The electrical system is modest but effective:

  • Two 100W solar panels on the roof
  • A 100Ah lithium leisure battery
  • A 20A MPPT solar controller
  • A battery-to-battery (B2B) charger to top up from the alternator while driving
  • USB and 12V sockets throughout
  • LED strip lighting
  • No inverter — everything runs on 12V

In summer this system runs indefinitely. In a grey British winter it manages a long weekend comfortably.

Phase 6: The Lift

A 50mm spring and damper lift was fitted late in the build — Dobinson springs and compatible gas dampers. All-terrain tyres (235/65R16) were fitted at the same time. The difference was immediately apparent: the van sits confidently, tracks quietly on motorways, and handles green lanes and farm tracks without any drama.

The Result — and What We'd Do Differently

The build took seven months of weekends and occasional weekday evenings. Total spend including the van came to just under £9,000 — not cheap, but significantly less than the equivalent purpose-built campers on the market, and considerably more satisfying.

What would change on a second build? A proper compressor fridge rather than a coolbox. More storage under the bed. And starting the bodywork even earlier in the process, before weather and impatience become a factor.

But the van? The van is exactly what was planned. It's been to Scotland twice, through Wales more times than countable, and has spent nights in places no campsite would ever exist. That's what a T4 is for.