Converting our sturdy Mitsubishi Delica into an awesome 4×4 camper van

Last updated on 24 Nov 2022 by Thierry

What appeal to us into becoming more nomadic is the possibility to stop to places we choose (most of the time!), enjoying the surroundings and having a good time, with no or fewer boundaries and limited constraints. In short, living your life. A better life. Being nomadic includes mobility. How this quest for freedom leads us to “converting our sturdy Mitsubishi Delica into an awesome 4×4 camper van” and how to do that?

Well, we crafted this post based on our experience to help you on your way to your better life. You will find below information, step-by-step guides, links,… for the design of your future little home on wheels, and how to consider and integrate the different necessary systems such as electricity.

Note: this page is regularly reviewed and populated with information based on how we progress on our build. Check regularly for the latest updates!

Choosing our rig

How to combine mobility with the love for the grand and wild outdoors?

For us, it came as a no-surprise that we needed a 4×4, a van or similar. An MPV (Multi-Purpose Vehicle) was ideal for us, for its practicality, space and flexibility. It can be used to transport passengers with a very good level of comfort, or cargo – big volumes – with a flat floor. After research, we first spotted Mitsubishi Delica L300 as a 4×4 MPV, but quite quickly switched to the more recent and powerful Mitsubishi Delica L400. And it took us only a few months to find and finally buy our “modern” 26 years old Delica in February 2020.

Despite having in mind from the start that we would potentially transform our Delica into a more off-grid rig, we took our time and tried it for a few months camping around in the UK and in France, when the travel restrictions were eased during the pandemic.

And we were right to take our time, as our family extended in the meantime! 🙂

Now that our project has restarted, us learning vanlifers are going to present you with the main steps to turn a Mitsubishi Delica into a great 4×4 camper van.

Project scope (what you need)

That’s the first step and an important one. You need to take time to think about your project. Rushing this stage will result in a conversion which in the end will not answer your needs, either because you will have forgotten something important or just because it will not be practical. In short, you will not be enjoying your rig and will be regretting not having taken enough time thinking about your conversion. No pressure then!

We identify some strong requirements via a series of questions:

• How many people should the conversion accommodate (sleeping space)?
  • 2 adults and a baby
  • 1 cat
• Going to cook? Ok, this is a silly question… We are massive foodies, so we need:
  • A kitchen to prepare nice meals, being on the road does not change that
  • Reserve of potable water, and water management system
• What about storage? What we need to take with us:
  • Baby buggy
  • Baby “gear”: nappies, clothes, toys,…
  • Food (dry and fresh)
  • Clothes and toiletries
  • Storage for waking gears (shoes, clothes, rucksacks, walking sticks,…)
• Any other functionalities or things to consider?
  • A decent electrical system
  • Our conversion has to be reversible (if we need to have more seating space or space for cargo)
  • Our conversion has to be modular and flexible. For example, our baby is going to grow up, the buggy will go at some point and the space used for something else.
  • The project has to be affordable, meaning lots of DIY on the way (Yippee!)

Each requirement will be detailed in relevant sections.

As you can see from our list, we took time to think about our project. Despite this, I am quite convinced we will see some improvements once the system is built! 🙂

Choose your layout

Once you have defined the scope and listed your requirements, the fun begins. Choosing the layout makes you dream about your future life, but also starts a game: how you will organise everything you need into a limited space while keeping as much comfort as possible.

The layout will be based on the requirements you defined. Creativity is key here to ensure everything fits but you need to consider a few principles:

Weight distribution

Your vehicle needs to be balanced on its wheels. This means that the weight of everything that’s going to make the conversion needs to be distributed on the surface of the van. You don’t want your little home to be tilted on one side. It is not comfortable plus it is also very dangerous while driving.

For our 4×4 camper van conversion, we have identified three heavy items: the bedding/ storage structure, the water tank and the batteries for the electrics. The structure will sit across the van between the rear wheels, so not a problem. We have decided to install the water tank on one side and the batteries on the other. Doing this keep even out the weight and maintain the van’s balance.

Practicality

Everything should have multiple functions. As simple as that.

Because there is (very) limited space in your van, everything you decide to include should be carefully thought, be compact, and be multi-functions as much as possible.

For example, or cooking hob comes with flat and grill plates, which means we don’t have to carry frying pans with us. Also, we have chosen foldable cookware: imagine the space taken by a standard colander… Another example: the middle seat row of our lovely 4×4 camper van doubles as support for our bed.

Design the structure

What we all want is to get our hands dirty, however you should put back this hammer in the toolbox for the moment.

Now that you have your layout, it is time to design your structure. I mean a bit more precisely! Your layout is most likely hand-drawn on a piece of paper. The design will consist of creating a precise model of your future build, to validate all your hypothesis: everything fit as expected or not, any problem? (better to detect now than when half of your stuff is built and in place already…).

There are two possibilities for this design phase:

• 2D approach: you will need to draw to scale, still on a piece of paper, your design inside the van,
• 3D approach: using modelling software (CAD), you will be able to design and visualise your van’s interior.

The choice between 2D and 3D is a question of preference and knowledge. 2D will be quicker if you have never used a 3D modeller before, but learning to use CAD software is always a useful skill. Plus, getting a 3D model precise enough will allow you to skip or shorten greatly the “mock-up” phase (see below).

Once your design is mature enough, it is time to test it. As written above, if you have a 3D model detailed enough, you should be able to validate your layout as is. Otherwise, you will need to see in your van how things will really fit. You can be creative there again as there is not really a better method: cords, masking tape, cardboard,… The idea is to visualise the blocks making your design and check if there are any issues.

We have opted for a somehow “discreet” design, considering the requirements detailed before, in particular the flexibility/ modularity and the reversibility. That makes us having a main block containing drawers and storage compartments located above the rear axle, between the wheels, and 2 side blocks above each rear wheel, containing additional storage and technical installations, such as water management.

You can check the design of our 4×4 camper van in the video below:

From there you have the possibility to start building or continue to design, considering electrics and water management. Just keep in mind that you might have to modify what you will have already built when you start passing cables and hoses! 😉

Electric management

One of the key aspects of our 4×4 van conversion is to be able to stay off-grid for some time. Off-grid means being entirely energy independent. Obviously, for a camper van or any “normal” vehicle, you will still need some fuel to move from A to B but the off-grid capability will be crucial when staying in a place for some time. We need to ensure basic functions: keeping our food fresh, charging phones, having lights at night, being able to connect a laptop for working,… without the need to have the engine running (using our precious petrol or diesel and polluting the environment!) or being connected to the main.

Ok, but how to do that? How to turn my van into a fantastic off-grid camper?

Here the main goal is to have a battery big enough to power everything that needs to be connected on a typical day but also to have a charging system to replenish your battery (or batteries) at the same time. Some of the key elements you need to consider:

• Leisure battery (or batteries). Warning: those are different from your standard battery to crank the engine,
• Charging solution: solar panel + charge controller,
• Cables,
• Fusebox,
• Switches, USB and cigarette lighter sockets,
• Lights.

The batteries in cars are usually 12V, and that the same for our 4×4 camper van, which means all the circuit above will be a 12V installation. But what if you need to connect a fridge or a laptop charger? Then you will need additional equipment:

• Inverter, converting the 12V continuous from the battery to a 230V (or 110V if you are based in the US for example) alternative signal similar to a household one,
• Household sockets (type pending the appliance you will need to connect).

I really enjoy working with electricity, however working with electricity can be dangerous if you don’t know what you are doing, so you should look for some help if you have any doubt.

In order to provide you with more information, we have prepared a detailed guide to walk you through this stage, from estimating your power consumption to creating a full electrical diagram, and that will cover costs and installation.

Building the structure (do-it-yourself van furniture)

Where things are becoming real!

Once you have your design ready, you need to think about and choose, if not done already, which materials and assembly techniques you are going to use to build the structure.

To be honest, it will depend on the possibility of access to a garage, a power supply, and therefore which tools you could use. The most common materials used for van furniture (and van conversion in general) are:

• wood: plywood, sawn wood,…
• aluminium profiles and accessories (+ plywood, most likely)
• welded steel frame

The access to a power supply and garage gives you access to all options. Conversely, if you are building your furniture on the side of the road with hand tools and wireless tools, wood will probably be your best choice!

Following your design, the build will start with the understructure, which will support the panels and yourself (sitting or sleeping). Fitting panels will be the second step, for example, the platform on which you will be sleeping. Drawers and cabinet doors will come next and finally the finishing touch (painting and carpeting).

tip: before moving to the latest stage (carpeting and painting), take a bit of time to try your furniture. This is to be sure that what you have built works well, is fit for purpose, and that nothing breaks apart when you drive the van around.

Warning: for your safety and the safety of your passengers, don’t let the furniture loose at the back of your vehicle. You have to secure it, which could be by creating brackets and adding fixation points to the van, or simply using ratchet straps (the ones used to secure loads) attached to already existing fixation points (rear seat mounting points)

Check our dedicated post about making robust, lightweight and affordable furniture for your van for more details and guidance.

Coming soon

• Water management
• Install the electrics
• Install the water