Should you build a DIY caravan?

If you can’t find a caravan on the market that appeals and you have the space, time and skill set -- and wouldn’t mind saving some money -- it has become easier than ever to build your own van to your own design.

This is mostly thanks to the growing popularity of fibreglass or aluminium composite panels for many applications. Composite panels are much easier and quicker for a relative novice and expert alike to work with than old-school timber and aluminium cladding, and there are companies that specialise in the panel manufacture and have the automated machinery that can precisely cut to your measurements.

One such company is  Brisbane-based Styromax, which is a designer and manufacturer of fibreglass composite insulated panels for a range of applications such as mobile homes, caravans, trailers and truck bodies.

Styromax makes fibreglass RV panels in various thicknesses, CNC cut to requirements, as well as selling accessories necessary for a DIY build such as hinges, locks, finishing trims and adhesives.

According to business development officer, Samantha Massey, Styromax customers build a wide range of DIY caravans.

“We’re seeing customers from slide-on campers all the way up to, for example an over five-metre [caravan panels] I’m quoting on at the moment," she said. "We don’t have an average size or regular one that we’re doing. We're finding interest from the full range of the market.”

Styromax does not provide registration and insurance advice, but Massey said the company will “advise [DIY builders] if they're too wide or if they need to consider their doors, windows or awnings.

"As for the chassis design, we don’t get involved with that, we refer them to a chassis builder," she said.

Styromax also leaves the internal cabinetry fit-out and other finishing touches to customers.

While freight for a panel set can be expensive, especially to southern or western states, she said the cost savings over buying a ready-made van can more than make up for it.

“One customer was looking at a $120,000 plus spend on a new van; the panel set we sold him was $10,000 plus GST. Then of course you have to take into account the fit-out, accessories and things like that.”

What could go wrong?

If all you plan to build is a simple, small box camper with not much more in it than a bed and 12v lighting, it would make a pretty straight-forward home-garage project. In fact, this might be the perfect introduction to caravan building -- if you can get a basic box camper right, you'll have the confidence to go on to something bigger and better later.

However, there's no doubting the bigger and fancier you go, the more complex it gets...

If you're building a large caravan - let’s say a an 18-footer or bigger -- then you'll need a lot more covered space to work in than the typical garage or carport. An industrial shed is the go, and not all of us have access to such a workspace.

Not only do you need the extra space for a large van, you need the manpower. While composite panels are fairly light, large sections of it are going to need several people to secure in place, even if you’ve devised a you-beaut pulley system.

Then there's the matter of time . Although Styromax -- to showcase what could be done -- built a camper body, including fitment of accessories such as windows and door in 20 hours, it would take a lot longer than that for a complex build, such as a large luxury caravan. Realistically, hundreds of hours, from first drawings to road-ready completion.

You’d also have to ask yourself whether you have enough time to actually finish the project. Many don’t - one reason why Queensland's Zone RV quit the DIY market a few years ago to concentrate on full 'turnkey' caravans.

Massey agreed that the process can’t be rushed, saying that Styromax also needs time from confirming measurements to making estimates and freight quotes, to sorting the finer details such as how much glue is required and then slotting the order into the manufacturing queue.

“Realistically, you’re looking to build over six months; three months for smaller jobs," she explained.

Then there’s the matter of skill. The majority of Styromax’s DIY customers already have a certain skill set. According to Massey, “they're either a boilermaker or fabricator, who can do a chassis, or they're a chippy or cabinetmaker so they can do the internal fit-out.

"Then you have the people who have no experience in that area but may be an engineer or something like that, or have previous experience in design.”

There's plenty of interest in how to build DIY caravans, though, Massey explained, with Styromax last month for the first time offering a DIY workshop day.

The free event was booked out within 24 hours with more than 50 people wanting to attend, coming from as far as Cairns and Canberra. More workshops are planned for 2020.

“What we’re trying to do is cater to a particular build style," she said. "Next (workshop) is for an off-road van, another will be for a family van. Suppliers will also come to exhibit, such as accessories supplier Aussie Traveller and LED Autolamps”.

Experienced DIY builders including past Styromax customers, will also attend to answer practical questions.

Of course, the other issue if you’re building your own van, is to ensure it complies with not only the regulations around building a trailer that makes it safe to go on the road, but also electrical and gas compliance for the fit-out.

While the VSB1 trailer regulations are relatively simple to follow and are self-certifying (that is, it’s up to you to say you’ve built it to the VSB1 standard), it's recommended you get an engineering certificate before presenting it for registration.

That way you’ll catch any problems and have peace of mind that your freshly-built van is not a ticking time bomb...

With 240volt AC electrics and gas, a licensed installer must sign off on the work and certify that it meets required standards. Better still, like many professional caravan manufacturers you could sub-contract gas and electrical work to a tradesman with the appropriate licenses so that you’re completely sure the work is done to standard.

While building your own van will save you money, it’s not a venture for the foolhardy and unlike choosing a van from the caravancampingsales classifieds, you can’t expect to head off camping in your freshly-built van by next week...

Also read:

DIY woody caravan for under $20,000

DIY mini van floats Down Under

Why are there so many caravan makers?