Hey, I’m Ollie, and welcome to Episode 4 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 3 https://camperlux.co.uk/products/episode-3-install... we insulated the floor, walls, and sliding door while sealing potential leak points. Now, we’re preparing the van for carpet lining by addressing holes, insulating the ceiling, and starting the carpet lining process.
Step 1: Preparing Panels for Carpet Lining
The Crafter’s interior has multiple holes along the side panels that could let air and dust through, which might discolour the carpet over time. Here’s how I tackled this:
PVC Fillers: I cut custom PVC blanking plates to cover 16 holes on each side of the van, securing them with foil tape (Dial tape from Screwfix).
Wooden Panels: I reused the van’s original 5mm plywood, cutting a panel with a chamfered edge for one section and taping the edges to prevent air leakage.
Sealing Seams: To avoid air blowing through bodywork seams, I applied foil tape along all seams, including around the rear doors and windows, for a clean, airtight finish.
Step 2: Insulating the Ceiling
Before carpet lining, I insulated the ceiling to break the thermal bridge between the van’s interior and exterior, preventing heat loss and condensation:
Materials: I used 35mm Dacron insulation, cut to size, and applied with high-temperature contact adhesive from Harrison Trim. Regular adhesive won’t withstand the heat, so choose carefully.
Application: I sprayed adhesive on both the ceiling and insulation, let it dry briefly, then pressed the insulation into place, ensuring all gaps and strengthening bars were filled. Cable rods helped push insulation into tight spaces.
Why It Matters: Proper ceiling insulation keeps the van cosy and condensation-free, especially in colder climates.
Step 3: Carpet Lining the Walls
With the panels prepped and ceiling insulated, I began carpet lining the walls for a comfortable interior:
Materials: I used 6 meters of easy-lining carpet trim from Harrison Trim, applied with high-temperature contact adhesive.
Process: Starting with flat surfaces, I sprayed adhesive on both the panels and carpet, then used a carpet tool to press the material into corners and contours. I worked in two sections (front and rear) for better control, stretching and tucking the carpet for a seamless fit.
Details: Around windows and wheel arches, I trimmed the carpet carefully with a Stanley knife. I removed and reinstalled door stays and trim to ensure a clean finish. A suede-effect board will be added later over certain sections for a premium look.
Progress: The rear section, wheel arches, and around the barn door area are now fully carpet-lined, transforming the van’s interior.
Step 4: Starting the Ceiling Panels
To wrap up, I began fitting ceiling panels, which come in three sections:
Installation: Using a prop to hold the panels in place, I bonded them along the roof supports with contact adhesive and added screws to secure them tightly. These were left overnight to set.
Purpose: The ceiling panels will provide a base for further lining, enhancing both insulation and aesthetics.
Progress Recap
This episode brings the total build time to seven days. We’ve:
Covered holes with PVC blanking plates and foil tape, sealed bodywork seams, and prepped panels for carpet lining.
Insulated the ceiling with Dacron and contact adhesive.
Carpet-lined the rear section, wheel arches, and barn door area.
Started fitting ceiling panels, secured with adhesive and screws.
Added M6 riv nuts for future furniture attachments (table rail and bed frame).
As with my two previous Crafter conversions, I’m sharing this process to help you replicate it with furniture kits available at https://camperlux.co.uk/. These kits are designed to streamline your own van build.
What’s Next?
In Episode 5, we’ll complete the ceiling lining, install flooring, and continue building the interior. Follow along on YouTube for the next video, and check out https://camperlux.co.uk/ for furniture kits and supplies.
