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THE CAMPER CONVERSION MANUAL
1-1-3. A van with high mileage but lots of regular
maintenance and a full service history will generally
be more desirable than one that shows a lower
mileage but which has been knocked about and not
properly maintained.
carry out the conversion to a camper for us.
After all, Leisuredrive had converted our
previous VW Camper and six years of use
had seen nothing break, come loose or fall
off! And that’s where this book began.
There was once an advert for razors
where some smug-looking feller held up
a razor to the camera and said something
like, “I tried this razor and liked it so much,
I bought the company.” Well, I’m fortunate
enough to test drive quite a few vehicles in
the course of my work as a motoring writer
and I can honestly say, “I test drove the van
and liked it so much, I bought one!” Not as
spectacular a claim, perhaps – but at least
it’s true ...
SECTION 1. MODEL TYPES
Ninety-six models – which is right
for you?
A VW press release of 2006 posed the
above question of the T5 Transporter
– and it wasn’t even including the Caravelle
MPV range! However, it’s not as daunting
a choice as you might think and, buying
second-hand, you won’t have the detailed
choice that the new vehicle buyer enjoys.
However, there are several major categories
of Transporter available at the time of writing
and you’ll need to know which version you
want before you start looking because their
detail characteristics are quite different.
All the engines are powerful and
economical TDI engines and feature
Volkswagen’s ‘Pumpe Duese’ (PD) unitinjector technology. Other main features
include: long service and maintenance
intervals; independent suspension on all four
wheels and agile handling; superb, slick gear
change; ergonomic cab design with car-like
qualities and comfort levels.
Gross vehicle weights, at time of
launch, ranged from the T26 (2.6 tonne);
T28 (2.8 tonne); T30 (3.0 tonne) to T32
(3.2 tonne). The vehicle we chose is a T28,
to provide 200kg more carrying capacity
than the base vehicle, plus, we assumed,
more resilient suspension for a vehicle
carrying the kitchen sink around with it the
whole time but at very little extra cost.
1-1-4. The window van which has windows behind the cab but not at the very rear could be a good basis for
a conversion, but this is the Shuttle which has a sliding door on each side that makes it unsuitable.
All have:
• two wheelbases: 3m or 3.4m.
• three roof heights (only one for the
Shuttle).
VW’s designated model types are currently:
• The Transporter Panel Van.
• four gross vehicle weights.
• load compartment volumes of 5.8m3 to
3
9.3m
• seating for 3
The Transporter Kombi
• designed to carry up to 6 people in
comfort, and a sizeable load at the same
time.
• two gross vehicle weights.
• payloads of 1200kg or 1400kg.
• a range of door and window options.
• rubber flooring in load compartment.
The Transporter Window Van
• Volkswagen’s heavy duty answer to
passenger-carrying for up to nine people.
• range of seating up to nine, arranged in up
to three rows.
• a range of door and window options.
• tough rubber flooring.
• suitable base for conversions.
1-1-5. This cutaway of the Caravelle’s internal components gives a good idea of the vehicle’s structure.
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EXTERIOR STRUCTURAL WORK
2-5-A12. Those cut lines are now connected up, across the back of the roof …
2-5-A13. … following this rib down the length of
the roof …
2-5-A14. … and across the front, just behind the
front door. Anyone carrying out this work for the
first time will need to refer to the Reimo fitting
instructions and the dimensions of the reinforcing
sections supplied, as well as noting the variations
that Barry built into this particular job as shown later
in this chapter.
2-5-A17. Barry started at the front …
2-5-A15. Barry used his drill to make a series of
holes which he then linked together by pushing
sideways carefully on the drill (if you’re not careful
the drill will break!). Note that in this instance,
where he needed to begin cutting through a double-
sided panel, a slot needed to be made in both
sections.
2-5-A18. … and cut straight across to the other
side. 2-5-A19. He cut down the length towards the back …
2-5-A16. Barry pointed out that the jigsaw blade
he used had to be long enough to cut through the
widest box section.
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