Hey, I’m Ollie, and welcome to Episode 3 of my blog and YouTube series, where I’m converting a medium wheelbase VW Crafter into a 4-berth, off-grid adventure vehicle!
In Episode 2 https://camperlux.co.uk/products/episode-2-install..., we fitted windows, installed an awning rail, and lifted the factory floor. Now, we’re diving into insulating the floor, walls, and ceiling, plus sealing potential leak points to ensure a watertight, cosy camper.
Step 1: Insulating the Floor
With the factory floor lifted, I continued preparing the base for insulation and utilities:
Fitting Insulation: I cut and placed one and a half 25mm Kingspan boards between the roofing battens, leaving the 70mm channel free for utilities (water pipes and electrical cables).
Next Steps: The factory floor will be reinstalled later after further utility work, ensuring everything is neatly tucked away.
Step 2: Insulating the Walls and Wheel Arches
To create a warm, quiet interior, I insulated the van’s walls, wheel arches, and ceiling using a combination of materials:
Dodo Thermo Liner: I used 6mm foil-backed, self-adhesive Dodo Thermo Liner, as a sound deadener and insulator. After wiping down the panels with isopropyl alcohol for a clean surface, I applied the liner to the wheel arches, wall panels, and ceiling. This reduces road noise, as demonstrated by a tap test showing a duller sound post-insulation.
Dacron Insulation: On top of the Thermo Liner, I glued 35mm Dacron insulation inside the wall panels, leaving a small gap at the bottom to prevent water or condensation buildup. For hard-to-reach pillar areas, I used a cable rod to push Dacron into tight spaces.
Finishing Touches: I applied foil tape (Dial tape from Screwfix) over seams for a neat finish and doubled up insulation around windows for extra protection.
Material Note: I used 10 meters of Dodo Thermo Liner and 15 meters of Dacron but ran out, so I’ll need more to complete the back doors.
Step 3: Sealing Potential Leak Points
To keep the van watertight, I addressed several areas prone to leaks:
Sliding Door Rail: The rail’s 10mm nuts were unsealed, so I removed them, applied SikaFix sealant, and reinstalled them.
Roof Grommet: A paint-held grommet at the rear roof was sealed with SikaFlex to prevent water ingress.
Roof Gutter and Pop-Top Screws: I poked through circular stickers covering roof rail holes and sealed them, along with tech screws from a previously fitted pop-top, using SikaFlex.
These steps ensure the van stays dry, protecting the insulation and interior.
Progress Recap
Over the past two days, we’ve:
Battened and insulated the floor with Kingspan, leaving a utility channel.
Insulated the walls, wheel arches, and sliding door with Dodo Thermo Liner and Dacron.
Sealed potential leak points on the sliding door, roof, and pop-top screws.
This is my third Crafter conversion, and I’m sharing this process to help you understand how to prep a van for a furniture kit, like those I produce and supply through https://camperlux.co.uk/products/intrepidvan-furni... These kits are designed based on my personal builds, perfect for replicating this off-grid setup.
What’s Next?
In Episode 4, I’ll cut wood for side panels, insulate the ceiling, and start carpet lining the walls and ceiling to create a cosy interior. Follow along on YouTube for the next video, and check out https://camperlux.co.uk/for furniture kits and supplies.
