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How to renovate a caravan - Part 1

Peggers
Becoming a Leader

How to buy a retro caravan

 

Difficulty: Intermediate

 

A retro caravan can offer the freedom to relax and get away from it all, whether you tow it to a gorgeous holiday spot or leave it in the backyard.

 

This article shows you how to ensure you buy the right van to renovate. Don’t miss Part 2: How to fix an old caravan and Part 3: How to style a caravan.

 

You can also get inspiration from our collection of 10 caravan renovations by Bunnings Workshop community members. 

 

Steps

Step 1

First of all, you need to buy a retro van that’s within a reasonable budget. As a rule of thumb, vans from the 1980s or earlier shouldn’t cost more than $5000 for the whole project – that includes buying the van, restoring it and getting it registered.

 

Normally I try and find retro vans for around the $2000 mark, which allows $500 for on-road costs and $2500 for a complete renovation and fit-out, which includes everything from paint and materials to lighting and homewares.

 

If you can find a van in great condition that’s already registered and just needs a quick paint job, then $4000 could be an upper limit. But equally, if it’s a shell on wheels then you might try and pay $500 and decide to kit out the whole thing from scratch.

 

Pic 1 - Unrenovated van.jpg

Step 2

Make sure the caravan you’re buying can be towed straight away. That might seem obvious, but if a van is cheap enough then you may be tempted to use a flatbed truck to get the van home and try to mobilise it later. But I’m not a mechanic and don’t want to be fixing axles and wheels (or even changing tyres, to be honest…) Ideally, try to buy something that’s within a 50km radius and tow it home. Make sure you ask questions about when it was last towed and how far.

 

Pic 2 -Towbar cleaned up.jpg

Step 3

You can legally tow a van even if it hasn’t got a current registration. In all states of Australia (and also in New Zealand) you can obtain an Unregistered Vehicle Permit for a specified time. This is a low-cost way of getting a caravan home. In the longer term, you will need to get a certificate of roadworthiness that ensures it is safe to be towed – these are valid for 12 months. It’s best to do that after your renovation, rather than have the rego run down while you’re working on the van and can’t use it on the roads. Having said that, if you’re intending to keep the van on the road while you restore it (rather than in a driveway or garage) then you’ll need the rego straight away to avoid being fined.

 

3. Temporary registration.jpg

 

Step 4

Don’t worry if the caravan’s outside lights and indicators don’t work. You can buy a trailer light board to tie on the van for around a hundred bucks. It’ll be enough to get you home. In my experience, outside lights are usually relatively easy to fix. New bulbs and perhaps a new 12-pin plug are often all that is needed and are relatively cheap. Check the connections and you should be good to go – it’s usually an hour’s work at most.

 

4. Lightboard.png

 

Step 5

It is a much bigger concern if the electrics inside don’t work. Take an extension lead and spare household lightbulbs with you when you go to see the van, and ask to plug it into mains power. Mending a simple connection for the tail lights is one thing, trying to rewire the inside of a van is another. Try flicking a few lights on and plug in something like a phone charger to a few sockets (or better still, a power outlet tester plug). Updating lights to more modern models is straightforward, but a full rewiring takes time.

 

5. Electrics.jpg

 

Step 6

Is the caravan structurally sound? Above everything else, make sure the underneath bars aren’t rusty and that there are no major dents or holes. You can fix so many things inside and outside the van, but it needs to be a solid base. Also check if the water tank underneath is good. It can be replaced, but it’s such a painful and fiddly job. Surface rust is fine – it can be scrubbed off with a wire brush, covered with rust sealant, and then sprayed over in white, silver or black. But any extensive rusting of the framework should to be avoided.

 

6. Too much rust.jpg  6. Surface rust is fine.jpg

 

Step 7

Don’t worry about the interior too much. Floors can be easily covered with new stick on tiles fairly cheaply. Bunnings has an excellent range; MDF sheets can tidy up walls and ceilings. New cupboards can be fitted to replace old ones. It’s amazing what you can do with just soap and water. And then No More Gaps and some white undercoat paint can work wonders. Even an empty shell can be renovated as long as it’s solid. Likewise, the outside paintwork can be cleaned up whatever state it’s in – dirt, graffiti, you name it. But major dents or holes are hard to knock out pleasingly or fill perfectly, so avoid vans with major bodywork problems.

 

7. Floor Before and after.jpg

 

Step 8

Don’t be scared by leaks. Even water damage isn’t terrible. It may look like the symptoms of a bigger problem (and occasionally is) but we’re only talking about a room on wheels here, rather than a house. I usually seal every joint outside on the roof with No More Gaps to make sure it’s water tight whether it’s leaked in the past or not. You can make everything watertight within a couple of hours.

 

8. Water damage.jpg

 

Step 9

Furniture and appliances and easily replaced. You can replace sinks, cookers and taps if you need to. You can completely gut the van from scratch and start again if you like. But obviously the more that works the better, as it’ll speed up the project and make things cheaper. It’s handy if cupboard doors and handles are salvageable as they retain that retro feel and can blend nicely with the modernisation.

 

9. Kitchen before.jpg  9. Kitchen after.jpg

 

Step 10

While doors and windows can be fixed, it’s far better if they’re in working order when you buy the van. While you can fix most interior stuff from Bunnings, the latches on doors and windows are specialist caravan ones and replacing them gets expensive. You can fabricate stuff from metal and plastic but it’s hard. I once used a garage lock to fix a caravan door and you may need to get creative with solutions to save cash.

 

With all that in mind and your caravan towed home – it’s time to renovate! Another 10 tips will follow in the next instalment

 

10. Damaged door.jpg

Materials

  • Rope
  • Household light bulbs (bayonet and screw-in)

Tools

  • Screwdrivers (flat head and Phillips)
  • Torch
  • Power outlet tester plug
  • Trailer light board
  • Extension lead

Images

1. An unrenovated van.jpg

2. Towbar.jpg

3. Temporary registration.jpg

4. Lightboard.png

5. Electrics.jpg

6. Too much rust.jpg

6. Surface rust is fine.jpg

7. Floor Before and after.jpg

8. Water damage.jpg

9. Kitchen before.jpg

9. Kitchen after.jpg

10. Damaged door.jpg

33 Replies
Beaver
Finding My Feet

Hi 

Reading Part 1 to 3 has my wife and I thinking we can do a renovation after reading and looking at the photos.

 

Question1 - if the interior of the van including ply walls have been removed then this would be the time to rewire the van for 12v and 240v to where you plan to have outlets including internal positions for 12v led lighting?

 

Question 2 - What type of paint are people using to paint the exterior of their vans is it 2 pack?

 

I am sure there will be more questions to come.

 

Regards Beaver

 

 

Jason
Community Manager
Community Manager

Hi @Beaver,

 

Great to see that @Peggers's advice has given you the confidence to tackle your own caravan renovation project. We look forward to seeing it! I would recommend you hit the Start a discussion button and create your own thread so that members can follow your journey. 

 

Hopefully Rob can answer your questions about rewiring and painting as soon as possible. I know he is not a fan of doing any electrical work though!  

 

Welcome to the Workshop community. We're rapt to have you join us and trust you'll get loads of helpful advice and inspiration from our clever and creative members.

 

Jason

 

WendyLS
Getting Established

Perfect! Looking for a van right now to use as a sleepout. 😊

Old-gal24
Becoming a Leader

Hello @Peggers 

 

Rob I am wondering if you would mind helping me with a few questions that I have regarding the best way to find out a few things that I need to do on my little caravan, hope you don't mind?   What's the name of the silver aluminium joining strip/trim? that you use around the edges and joins on the outside of the caravan and where can I purchase it from?

 

Secondly, can one purchase just the rubber seal that goes around the windows of a caravan?  *(the rubber that seals the windows into the walls of the caravan?), and where I could purchase them from as mine are all splitting and I've been told just use Silastic to fill the splits, but fee it would look bodgie and I would rather have it look nice and neat.

 

So far I've - stripped back the draw bar, and re-painted it, had new wiring - electric brakes - anderson plug system from car to caravan etc.re:padded and cover the seats and back rests and made new curtains.  I have blinds to install also as the van has 3 large windows, at seating area and each side of the bedroom at the back.  It's only a 17 ft Windsor, semi pop top.  I would like to install a wind out awning and re-paint the caravan inside and out. Not exactly sure which is the best paint for those jobs but I think you mentioned that in one of your steps.  Which I will have to re-read.

Oh well those jobs will have to wait till later in the year as I have to get lots of jobs completed at home first.

 

Hope you don't mind me picking your brains?  I just adore what you have shared with us.  You are a very talented crafts man.

 

Old Gal

Peggers
Becoming a Leader

@Old-gal24 

 

Glad you like the vans!

The aluminium joining strip we use is actually the strips you use to edge carpet. Go to Bunnings where the floor tiles area is and you'll see 3m strips of it. It's perfect for edging work.

 

The rubber seal that goes around the windows in the van we've had to purchase online from a specialist caravan place. We have occasionally used some clear silicone gel and painted over that - but you're right, it never comes up as nicely.

 

Sounds like you're well on the way! We do a final kit out at K-Mart normally, and most materials come from Bunnings.

 

 

Yolli
Growing in Experience

Awesome van, I’m currently renovating a 1981 pop top van. I found stick on tiles don’t work for a backsplash....lol...this has given me so many ideas, thanks

MitchellMc
Bunnings Team Member
Bunnings Team Member

Welcome to the Bunnings Workshop community @Yolli. It's a pleasure to have you join us, and many thanks for jumping into the conversation.

 

I trust many of our community members would be thrilled to follow along with your project, and we'd encourage you to start a discussion on your build. I know I would find it fascinating as I'm currently considering a homemade camper. I'm still in the design phase and have been making some models to get an idea of what will work.

 

We look forward to hearing all about your projects around the house and garden, and please let us know if you ever need assistance or have something to share.

 

Mitchell

 

Yolli
Growing in Experience

My first renovation was a 1983 Viscount wind up camper, unfortunately I didn’t take any before pics, but it was a full Reno, including new canvas (which we outsourced to a professional.)All the inside work was done by hubby & I. I’m a seamstress so I did all the cushions. I love flamingos, so had to incorporate them in there somewhere..

We have sold this one, now I’m  doing a 1981 viscount pop top, ongoing as I’ve run into a few probs.58CD509E-26AF-4200-B3B0-DBC43318A86E.jpeg1BB8304C-4AAF-491A-B511-545E5D4D3DBA.jpeg3CE4D1E8-81D7-45CD-9099-B4364252471D.jpegA22A3ECE-57E1-414E-9391-FA6A2D0F006F.jpegE74BE88C-0C14-4D9E-BEDD-C4833FC7952F.jpegD570125A-2695-4E08-B89F-5B332A2A3DA8.jpegI love flamingosI love flamingos543765E4-84D5-44F7-8B96-0DE6AA9EDE34.jpeg

Peggers
Becoming a Leader

@Yolli Great job! Keep posting pics of of the van you're working on!

BlueRose
Just Starting Out

Hi,

Are there are brochures on furniture fit out like the one use in this one?

MitchellMc
Bunnings Team Member
Bunnings Team Member

Welcome to the Bunnings Workshop community @BlueRose. It's sensational that you've joined us, and many thanks for your question about this inspiring project.

 

Let me mention @Peggers to see if he can assist with your question.

 

Do you have your own caravan you a renovating? I trust our members would love to follow along with your project, and I'd encourage you to start a discussion about it so you can document the process and so our knowledgeable members can provide assistance if needed.

 

Were you interested in a brochure of retro-styled cabinetry, as most of it in this project is original and just given a paint refresh? However, I can see that he's installed a new timber benchtop and sink. In How to renovate a caravan - Part 2 and How to renovate a caravan - Part 3, he goes into a bit more detail about refitting the caravan and how he's used various products from Bunnings.

 

It would be great to hear a bit more about what furniture you were interested in, and I'm sure @Peggers will be happy to assist.

 

Please let us know if you have any questions.

 

Mitchell

 

starofbasel
Finding My Feet

Hi, is it worthwhile to remove the old plywood wall to put foil isolation behind it? Is there enough space in a 1980 Millard micro for insulation? 
The poptop ceiling could do with insulation too, can foil be used? Can marine vinyl be used on top of the foil

MitchellMc
Bunnings Team Member
Bunnings Team Member

Welcome to the Bunnings Workshop community @starofbasel. It's sensational to have you join us, and many thanks for your question about renovating a caravan.

 

Important note for our New Zealand readers:

 

The New Zealand Ministry of Business, Innovation and Employment (MBIE) issued a ban on the use of foil insulation in July 2016. The ban applies to the installation and/or repair of foil insulation in residential buildings. However, given that the ban is due to a potential electrical hazard and caravans also run 240V power, the same dangers could apply, and caution should be taken with installing these foil products. More information is available here: Foil insulation ban | Building Performance

 

Foil insulation will online provide a limited insulation value and, by itself, would only achieve within the realm of R0.1. That's next to nothing and wouldn't warrant pulling your wall skins off. Insulation batts or foam insulation on the other hand will significantly improve the thermal value of the caravan and starst around R1.5, 15 times greater than the insulation value of foil. Obviously, those with better insulation values are thicker and need more space to install. If you did wish to go with the foil insulation, I'd recommend you employ the services of a professional installer.

 

You might need to do some exploratory work and provide some images so our members can better understand what insulation products will work on your Millard Micro. 

Let me mention some of our caravan enthusiasts, @Peggers, @Old-gal24, @twocutekelpies, @FloTheCaravan, @twocutekelpies and @VickiD, to see if they have some thoughts on insulation.

Mitchell
 

twocutekelpies
Making a Splash

Hi @starofbasel absorbent insulations are not recommended in caravans due to condensation and their tendency to leak, foilboard and styrofoam are very popular, usually 10-15mm thick with an air gap between it and the cladding.  It's advisable to run 240v wiring through conduit to avoid contact with foam as they can react with each other. I'm guessing foilboard is not available in NZ but I'd say styrofoam sheets are. 
Not sure about the marine vinyl, caravan lining is usually 2.7-3.2mm plywood, often poly or paper coated. Check out the decorative ply range from Forest 1, they stock a range of caravan ply that is poly coated so no need to paint. http://forest1int.com/products/#products-decorative You can order samples from them but can only order via a stockist such as Bunnings Special Orders desk. This is what I used in my caravans, looks great and easy to work with. 

julietbalcony
Just Starting Out

Can someone let me know where do I find Chassis number on my Franklins Regent Caravan 1974.

Akanksha
Projects Editor
Projects Editor

Hello @julietbalcony,

 

A warm welcome to the Bunnings Workshop community. Great to have you join us, and we trust you'll find Workshop a great resource for lots of handy D.I.Y. advice and inspiration for your home and garden.

 

Thank for your question on finding your caravan's Chassis number. Our resident Bunnings D.I.Y. expert @EricL will be back on the site tomorrow and will be happy to assist you with this. 

 

Let me also tag @Peggers and @twocutekelpies to see if they can offer any help in the meantime. 

 

Thanks

 

Akanksha 

twocutekelpies
Making a Splash

Hi @julietbalcony as the owner of a 1974 Franklin Regent myself, you should find your chassis number located as per the red circle in the photo below. 😊 I'm told the V in the number represents year built and the number is her production sequence.

  chassis number.jpg

Cocoplum
Building a Reputation

This is a cool project I would love to try💜

EricL
Bunnings Team Member
Bunnings Team Member

Hi @Cocoplum

 

Let me tag @Peggers to make them aware of your kind words. I totally agree with you, this is the kind of project you can really get into and get a fantastic result and a spare room to use. If you ever find yourself in possession of a caravan to renovate, please make sure to post an update. I'm sure our members would be keen to follow along as you rebuild it.

 

Eric

 

Dargus1234
Just Starting Out

When resealing the outside of a caravan do you need to remove the old seal

twocutekelpies
Making a Splash

@Dargus1234 for best seal, you need to remove the old sealant before applying new. Be aware of the possibility of asbestos in the original sealant if it's an old van and mastic was used, take precautions not to use anything that can make it airborne. A heatgun on low and a scraper often works to remove this rather than a wheel on a grinder or drill. Lay a tarp/plastic on the ground to collect the scrapings and wear PPE. 

MitchellMc
Bunnings Team Member
Bunnings Team Member

Welcome to the Bunnings Workshop community @Dargus1234. It's wonderful to have you join us, and many thanks for your question about rejuvenation caravan seals.

 

It's great to see you've already received a reply from one of our caravan experts. @twocutekelpies is quite renowned in the caravan renovation community. I'll encourage you to listen to the advice when potentially dealing with asbestos and wear appropriate PPE, including a facemask, gloves and disposable overalls.

 

You might also like to start a discussion about your restoration, as our members love a good caravan project. Please let us know if you have further questions. 

 

Mitchell

 

Cackles
Finding My Feet

IMG_1473.JPG

IMG_0482.JPG

I have an old 1970's Concord fibreglass caravan that desperately needs renovating. 

It has a kind of material ceiling that has holes in it & now needs completely replacing. The problem is it's not a flat roof like most caravans, so what can I use to reline the ceiling if I take it all out? 

 

Also, any ideas on how to get a slight dent in the roof out. I gather heating it on both sides and then pushing it out might be the way?

EricL
Bunnings Team Member
Bunnings Team Member

Hello @Cackles 

 

Welcome to the Bunnings Workshop community. It's wonderful to have you join us, and thank you for sharing your question about updating your caravans head liner.

 

I believe they call that material (PU) polyurethane leather perforated plaid fabric, its sometimes foam backed and acts as insulator and sound proofing material. I suggest holding off on the removal of your headliner until you find a suitable replacement. 

 

If I recall in my automotive class, this type of headliner with the dips and valleys has a rib inside that is mounted to the middle and sides of the roof. Due to the constant movement and exposure to hot temperatures the liner will eventually begin to deteriorate. Just keep in mind not to throw away the rib support and to keep the old headliner as a pattern guide when you get your new headliner material.

 

In regards to fixing the dent in the roof, I recommend making a jig with a round head pusher that will push on the damaged area while you are heating it up. The trick to maintaining the shape is to keep the jig in place until the fiberglass has totally cooled off. Once the fiberglass is back to normal temperature you can remove the jig.

 

Please remember to wear personal protection such as gloves, goggles and dust mask when working on your caravan. 

 

Let me call on @Peggers and @twocutekelpies for their recommendations.

 

If you have any other questions we can help with, please let us know.

 

Eric

 

Mandy007
Just Starting Out

Hi, i have an old caravan which needs a lot of work inside and out. [I already had my van prior to finding this site so I have managed to fail part one of the van makeover as my van cost less than $2,000 so it is in very poor condition]. I'm a little confused reading the forum and am finding it difficult to understand where to start. Is it possible to watch and learn as someone is repairing their van. I need to repair/attach external j rails and replace internal timber structure. I'm having trouble getting started. I'm located in Tallong and can travel between Goulburn and Mittagong for advice. Regards Mandy

twocutekelpies
Making a Splash

Hi @Mandy007 

Welcome to the Bunnings Workshop Community.  It sounds like you've taken on quite a project. Unfortunately, I'm a bit far away from you for local guidance but can I suggest you check out Rover Tasmania on You Tube, he covers quite a bit of his caravan renovations in detail and I found his videos a great help when I embarked on my first reno so many years ago. One of his videos for j-rail sealing is here Millard Caravan J-Rail Re-seal

 

Many others have done similar videos and you'll probably find them come up on the side under suggested videos. The hardest part is cleaning up as you go, so small sections at a time so it doesn't set and get away from you. This is a post from one of my caravans where I used masking tape to help with clean up 1973 Ambassador  I use Sikaflex Pro but there are a few schools of thought on which sealant is best for use on caravans, many repairers say silicone is the only way to go but if you're painting after sealing, the paint won't stick to it. Some say old school mastic but it does stay soft and can be quite a dirt magnet. I like Sikaflex because it can be painted over (as long as left long enough to fully set). I've left it uncovered on my Ambassador and it has attracted dirt etc but most has come off with a brush while washing the van. 

Regarding internal timber structure, if you're removing the wall lining, it can pay to add timber noggins to your frame to be able to fasten overhead cupboards etc to them. Caravans were originally built from the inside out, so cupboards were nailed/stapled in place from outside before the cladding was put on, as this can't often be done, the noggins help as a replacement option. Check out this link where I've built a bed base and added framing in across the back to suit. 1972 York  

 

I hope the above helps and I look forward to seeing you post your project in the Workshop Community. 

Shelley

 

MitchellMc
Bunnings Team Member
Bunnings Team Member

Welcome to the Bunnings Workshop community @Mandy007. It's a pleasure to have you join us, and many thanks for your question about caravan renovation.

It's wonderful to see you've already received some expert advice from Shelley (@twocutekelpies). If you haven't already come across them before, they really are extremely knowledgeable in the world of caravan renovation, and I'm sure they'd be more than happy to answer any of your questions. The rest of the community is also here to provide information and guidance on tools and materials you might need. I'd encourage you to read through some of the many discussions we've had on the community so far, as I'm sure many of your questions have already been covered.

 

For some great inspiration, check out these 10 caravan renovations. If you see anything in those discussions that you'd like to do yourself, feel free to drop the contributing member a message in their discussion so they can provide assistance.

Please let me know if you have any questions.

Mitchell
 

2suzette
Finding My Feet

Fantastic job, looks amazing & was great to read each step, thanks for sharing @Peggers. We have completed cosmetic renovations inside & out on our van which is a 2001 model, so not quite retro, but we love her. Originally I was thinking of painting the timber cabinets, but I thought of an alternative & decided to go with a boho vibe & keep the timber. I covered the middle insert of each cabinet with a rattan patterned adhesive vinyl film instead. I am handy on the sewing machine, so I sewed new curtains & made new covers for the couches & just a few other little decor tweaks with soft furnishings, to make it feel homely.

On the exterior, we removed the old decal with a caramel wheel & painted a new design over where the old decal was, instead of applying a new decal, as we wanted a different look to the original. We used Dulux Weathershield in a Dulux colour called Puddle.

2suzette
Finding My Feet

Here are some before & after pics of our cosmetic renovations to both the interior & exterior of our van mentioned in my previous post.

Screenshot_20210915-183827.png

 

IMG_20211127_123325474.jpg

IMG_20220917_131525215.jpg

IMG_20230527_175350.jpg

IMG_20230601_190245.jpg

MitchellMc
Bunnings Team Member
Bunnings Team Member

Welcome to the Bunnings Workshop community @2suzette. It's fabulous to have you join us, and many thanks for sharing your wonderful project.

 

You've done an amazing job, and I'm sure you're very proud of your efforts. The inside looks so much more inviting now. Do you get away much in it much? I trust it's a real treat.

Thanks again for sharing, and we look forward to hearing about all your other projects and plans around the house and garden. Please feel free to reach out anytime you need assistance or have something to share.

Mitchell
 

Snottygobble
Just Starting Out

I am fortunate in being able to take on this project as a means to see a little more of Australia in a less expensive way, but many folk are not so lucky & are having to choose a van as a mobile home permanently so lets make BUNNINGS the go-to place for all their  home requirements too!!🤗

Jason
Community Manager
Community Manager

Welcome to the Bunnings Workshop community and many thanks for the feedback @Snottygobble. We do have many keen caravan renovators here in the community, including the amazing @Peggers who created these step-by-step guides for people wanting to take the plunge and renovate their own van. 

 

At present, discussion about caravan projects takes place on our Outdoor board. If we see sufficient demand we might consider a dedicated space in the future.

 

We look forward to reading more about your own projects and plans.

 

Thanks again,

 

Jason

 

Snottygobble
Just Starting Out

It is really good that your OUTDOORS board includes caravan renovations , however because they are so different to work vans being repurposed those of us with these intentions have so many different challenges particularly those that encompass sound deadening, insulation & covering of the thin metal walls & floor of a work vehicle!  Then of course there is the wiring in of 12volt components, such as water pumps, roof vents with fans, fridges, heating, cooling using extra batteries & inverter often powered by solar panels which also boost the engine battery as well  . Choice of either electricity, gas or butane cylinders for cooking have rules & regulations ( in Australia) which can disrupt otherwise good planning for such a small area !  Then there is condensation to consider also!  I would love to see BUNNINGS being able to offer this growing band of Aussie enthusiasts the same choices as those in the USA , the UK & Europe  where products such tiny basins, twin gas burners ,soft hanging storage pods, swiveling tables, & even pure insulation wool ( Havelock) is available to them & sent all the way from NZ yet not to Australia! 

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