Hand Crafted Off Grid Winter Equipped Adventure Van (2012 year)

THE BUILD:

Wood burning stove:

BURLEY Springfield model. Thermal output 3KW, Energy efficiency 89.3%. One of the most energy efficient clean burning stoves on the market today for the cleanest combustion. DEFRA-approved and legal to use in smoke controlled areas. This wood burner makes for the stealthiest winter street park up – I’ve used this stove parked up in built up urban areas, attracting minimal attention. It’s so efficient that once up to temperature, it barely emits any smoke or fumes at all which means it can be used without unwanted attention and go unnoticed by all but the most observant passers by. Mounted on a real slate base, it is externally air fed through a floor vent for complete health & safety compliance and peace of mind. The flu is securely attached to the bulk head insulated panelling via the Schiedel stainless steel bracket, customised with an aluminium and wood support with copper screws for a beautiful and sturdy finish.
SCHIEDEL manufacture the highest quality twin wall stainless steel flues and roof mounted chimney Cowls. Their products are widely recognised as the best in home wood burning stove installations. The flu and cowl are mounted on the roof using four custom made manufactured industrial stainless steel rings, each one is a quarter inch in thickness. All are bolted together either side of the van metal skin, three on top of the roof and one under it, for a rock solid instal solution and then sealed with Envirograph. I watched many youtube camper van construction videos with fitted wood burners, and have never seen anything designed as well and with as much thought for longevity and safety as this. The stove itself is of sufficient size to burn logs of a size which allow hours of burn without constant re-fuelling – the external vent can be closed down for a gentle burn throughout a night if dense fuel such as oak logs or similarly dense woods are used. Small, fast burning logs are a real negative issue with tiny stoves. It took many hours of planning and the execution of the installation required absolute precision for a perfect result. Winter trips have been beautifully cosy and I can honestly say the burner is the heart and soul of this camper van build. 

Fan:

FAN-TASTIC VENT FAN. Manual opening upgraded with a double bubble glazed clear lid upgrade for maximum insulation in cold weathers and natural light. The fan has three speeds and blows air in both directions, as required, with thermostatic control which I have always used set to cold for manual continuous operation. For additional strength, when I installed the fan on the roof, I upgraded the design with additional aluminium flat bars on each of the four edges of the fan, custom made to make sure the fan wouldn’t ever warp or crack in extreme temperatures. The fan is sealed all round with the correct lap sealant, which shows absolutely no signs of delaminating from the metal roof – 100% resistant to any water ingress since installation.

Solar Panels:

Panasonic HIT N series 330W all black panels x 2 for 660 Watts total. Wired in series, rather than parallel, for maximum power generation in all weather conditions, using the highest quality Victron PV cables and connectors.
These solar panels were state of the art when I bought them new in 2018, with an industry leading efficiency of 19.7% using state of the art manufacturing techniques for maximum performance. I chose these panels because the construction made them ideally suited to potential vibrations from a vehicle instal. The Panasonic Heterojunction with Intrinsic Thin layer design solar cells are made of a thin mono crystalline silicon wafer surrounded by ultra-thin amorphous silicon layers – perfectly resistant to moving vehicle vibration. 
The two panels are joined together using single length 8mm thick aluminium angle which run the whole length of both panels on each outer edge for maximum structural rigidity, avoiding any flex in the panels themselves which could damage the copper cells and the wiring between them. Both panels were lifted onto the roof bars in one piece using a tractor! 
The panels which are effectively one, are then securely mounted on the VAN GUARD Ulti Bar+ roof system. The three inch gap between the roof and the panels ensures the panels do not become overheated and suffer damage when used in extreme heat conditions. The four bars are equally spaced along the length of the two panels for maximum strength and rigidity, and the panels are securely attached via the aluminium angle frame using tamper proof marine grade steel nuts and bolts with serrated washers.
The Van Guard roof bar attachment plates are secured to the van roof through the factory Mercedes roof channel holes. Before fixing, each plate was sealed with silicon underneath and then after, all around the edges with a thick bead of sealant for a reliable and long lasting weatherproof seal. Six years after installation there are no signs of de-lamination and the seals are 100% waterproof – absolute peace of mind for years to come.

4G  ANTENNA – omni-directional & custom made + WiFi ROUTER by EE:

Also on the roof is the 4g omni-directional mast attached to the roof bars using another aluminium custom made L mount. This connects to the EE 12V wifi router inside the van for continuous reliable fast internet access and phone usage. The router is unlocked for use with any SIM card. (Because of the continuous aluminium vapour barrier which envelops the interior floor, walls, and roof of the van interior, mobile network signals are so weak inside the van that they are almost useless, (unless you have the door open, or stand under the fan vent, which isn’t exactly practical). The router solves this issue completely and makes this build the perfect camper van for digital nomads requiring a reliable internet connection.

The Victron PV cabling from the 4G Antenna, and the solar panels themselves, enter the van through the roof throughbp four SCANSTRUTT ip68 rated dome ultra strong seals. Scanstrutt products are designed exclusively for the marine boating industry, and so are the perfect solution for external to internal cable routing in van builds. The dome materials are uv-stable and resistant to salt to be hard wearing, and so will never crack and leak. The bungs in the dome structures are pre-drilled, available in a range of diameters, but most importantly are split, which allow very easy replacement if required in the years to come. There is absolutely no chance of leaks gradually developing from the roof, and should you want to check on the condition of the bungs for peace of mind, just pull out the EXTEND&CLIMB ladder conveniently stored behind the drivers seat, and take a look. For solar panels to perform optimally they should be cleaned regularly, so it might be worth giving the panels a wipe down while you’re up there 😉

The solar panels, chimney cowl, fan vent and Antenna have proven to be rock solid and have coped easily with speeds of 80mph on motorways without any negative effect. I also experienced severe gale force winds while I was parked up during a bicycle trip in the lake district in late November 2021. The van was swaying from side to side, but there was no damage to anything at all on the roof. The system is bomb proof and can be totally relied upon.

Tyres:

After a great deal of research, I chose top of the range Michelin 4 season tyres for absolute piece of mind on all terrains and any conditions. I have parked in muddy fields without any traction issues, and I drove back to Oxford from the Lake District in pretty extreme snow conditions which left many vehicles stranded on the roads, and never had an issue, even on ascents and descents. The tyres still look new as to be expected with less than 10,000 miles on them.

Solar Controller and Battery:
BLUETTI AC300 Portable Power Station + B300 Lithium Ion Battery.

This was the last part of the build jigsaw and once installed make this camper van completely off grid. This state of the art system was purchased new from Bluetti in November 2022. There is too much information on the Bluetti system to list here, but it is state of the art, can be controlled and monitored from your smart phone using the bluetti app, has a huge inverter for clean 240V power to run sensitive electrical equipment like laptops, runs completely silently, and it integrates seamlessly via a Blue Sea Systems 12V fuse board with the electrical wiring installed and all hidden within the walls of the van during the first part of the build. The fuse board also provides power to the super low power draw DOMETIC 75litre dual zone fridge freezer, the fan, the router, various 12V usb-a charging points, and the 240V three pin double switched 13amp power socket, which also has intelligent smart 45W USB-C and USB-A sockets with built in overload protection for safe fast charging of all electrical devices, including power hungry modern laptops. As already mentioned, the huge battery and wattage of the panels make this van the perfect solution for any digital nomad, or serious gamer. The electrical system would also allow simple installation of a CCTV security system if desired. Due to the fortress style build, I didn’t ever feel additional security was required.

I have always cooked on gas, but the power of the solar system and the massive inverter in the Bluetti would easily allow for cooking on an electric induction hob if you wished.

Toilet:

I opted to follow Romany gypsy philosophy on having a portaloo in the van, though space can easily be created for one if buyer prefers.

Hook up:

The van does have an exterior connection allowing for campsite hook up charging. With the huge amount of energy available, I have never once needed this option, but it’s there for peace of mind. 
I opted for NEUTRIK POWERCON connectors simply because they offer a far stealthier look than the traditional huge 3 pin blue monstrosity connectors found on most conversions which immediately signpost vehicles as a camper vans and can draw negative attention. Neutrik connectors are known for their robust construction, and are designed to provide long-lasting performance in demanding environments. PowerCon is rated at 20Amps and up to 250 volts, more than compatible with caravan park electrical hook-ups which are designed for a maximum of 16 Amps, (though most sites actually limit current to 10, or even as low as 5Amps). The van is sold with the required extension cable, 10 metres in length, with the Neutrik connector on one end, and the 3pin blue connector for the campsite hook up on the other.

Fridge/Freezer:

DOMETIC CoolFreeze model CFX3 75DZ mobile compressor dual zone.
These CFX3 fridge/freezers are widely recognised as the best low power draw 12V solution, and I can confirm they are incredible, particularly this one, which has two huge compartments, each with individual temperature controls. Ice, iced drinks and keeping food chilled is no issue for weeks at a time with the huge lithium battery and 660Watts of solar on the roof. This truly is off-grid living. The unit runs silently, and has been positioned to provide the perfect seat, and sturdy step up onto the bed. There is a dometic app which allows bluetooth control from the comfort of the huge bed if desired, but I didn’t ever use it, preferring to use the digital controls on the fridge, (which also has it’s own usb charging point).

Insulation:

Before embarking on anything on this build, sound deadening was fitted to all the wall and ceiling panels. The entire floor, ceiling, the larger middle sections of the walls, and all doors are insulated using 38mm Xtratherm insulation boards (Celotex and Kingspan are essentially identical products). Due to the metal construction of the van, it was impossible to use the insulation board for the small lower and top sections of the walls, so they were insulated with rock wool. The floor, walls and ceiling are all sealed to form a continuous seamless vapour barrier, with every single join in each, and intersection between each, sealed securely using thick top quality aluminium tape. This continuous wrap of the interior to form a vapour barrier ensures that the warm and moisture rich air inside the van never reaches the colder interior of the metal van skin walls, where it would condense, and run down and collect in the cavities inside the bottom of van walls and rust the van from the inside out. This is IMPOSSIBLE with this van due to the meticulous way I have designed the build. In addition, use of the wood burner in the winter ensures there is zero dampness – a perennial winter problem in most van conversions.

Bed:

The bed is a Kingsize Japanese platform double bed built from solid wood, with a base constructed from two authentic japanese tatami mats bought new from the Futon Company. The organic futon is included. It’s a beautiful set up for comfortable nights sleep. No tedious morning and nightly setting up bed routine here, and being designed length ways means space for the tallest of people which is an issue in conversions with beds arranged in the opposite orientation. Despite the floating design, (rather than being on a floor) the bed is rock solid, with zero flex as it has been strengthened with solid steel bars for durability for two adults of any combined weight. Trust me, this bed doesn’t flex one millimetre. Beautifully simple in appearance with no supporting stilts, this design allows for an uninterrupted ‘garage storage space’ underneath. The marine ply floor in this ‘garage’ area has also been covered in a thick ribbed rubber grooved matting to allow care free storage for dirty bicycles, or wet surf boards, and super easy cleaning. With the addition of a small double sized mattress laid between the wooden clad wheel arch shelves, this clean uninterrupted space can also be used as a second berth for a third person, or cosy second couple if required. 

Storage:

Storage is open on the kitchen floor in four beautiful vintage apple crates which have been sanded to a smooth finish, treated with Danish Oil, with side panels and bases reinforced with copper screws for a super strength and durability. There is ample additional storage in the beautiful original vintage wooden storage boxes securely fixed onto the kitchen table and the shelving unit above. I decided this was far more practical, and aesthetically attractive than cupboards with doors. Everything is visible, easy to keep clean and tidy, and easily accessible.

In the bed area there are beautiful hand made asymmetrical shelves, suitably angled to accommodate the concave shape of the van walls, providing secure storage space for bed linen and easily accessible clothing.

Interior Materials:

The bulkhead wall, main walls and ceiling and rear doors are all clad in the highest grade Scandinavian tongue and groove pine. The boards were all ordered 4.3metres in length which were far more expensive, but means they run the whole length of the van, so there are no vertical joining seams anywhere, which results in a stunning finish. All the wood has been treated with Danish Oil and polished to a beautiful natural semi-gloss finish.

The floor in the living area is made using high quality pine tongue and groove floor boards, all screwed to the wooden subframe using copper screws. These boards were treated with a work top oil for durability and ease of cleaning, developing a lovely patina during my ownership, but I have sanded them down to a 320grit beautiful clean finish for the new owner, allowing their own choice of finish, or no finish at all.

General Design Brief:

Of highest priority and second only in design to the wood burner, was the need for STEALTH, and for SECURITY. I wanted to be able to be inside the van completely undetected by anybody outside, so I decided against having windows. Admittedly, this reduces natural light, but the clear roof vent allows a surprising amount of light into the van during the day with all doors shut, offers complete privacy, and provides just the perfect amount of light to wake up to in the mornings. The insulation and soundproofing means I can enjoy music at whatever levels I choose inside – indiscernible from the outside. This is the stealthiest most discreet practical van you will ever find. 
From a security standpoint, windows make a van vulnerable to opportunistic thieves, a problem experienced by some unfortunate van travellers in Europe who have returned to their pride and joy with windows smashed and their home emptied of all their belongings. With most of my worldly belongings in the van, and a very expensive Bluetti controller and lithium battery worth thousands of pounds, I wanted to be able to park the van anywhere, in the city, or exposed countryside, and feel confident it wasn’t going to be broken into. Without any windows, and double shackle locks on both the side door and the rear doors, I have never been worried to leave the van in unknown areas, sometimes while I am off cycling for days at a time. The same applies when I have left it on the street at home sometimes for weeks without use. Inside the cab, the 8mm security chain and double shackle padlock give total anti theft security. This van isn’t going anywhere unless you’re driving it.

I have many many additional photos, which I can send to interested buyers if they get in touch, including many of every stage of the build process which corroborates everything in this description and illustrates the careful design choices, the quality of the products used, the attention to every detail, and the hundreds of hours of work which went into this build. Everything in the photos is included in the price, and much more equipment making this van truly ready to leave on any adventure.