Embarking on a self-build camper van conversion is an exciting journey, and if you’re considering a Mercedes Vito Van as your base, you’re in the right place. Like many, we weren’t experts in electronics, carpentry, or mechanics when we started our own Mercedes Vito van conversion project. We had a vision, a basic plan, and a whole lot of enthusiasm. What unfolded was a fantastic learning experience, resulting in a camper van perfectly tailored to our needs. We made mistakes, discovered clever solutions, and now we’re eager to share our complete guide to converting a camper van, specifically focusing on how you can convert your own Mercedes Vito van. This DIY, self-built van conversion guide is packed with everything you need to know, including tips, regrets, and lessons learned along the way, ensuring your Mercedes Vito van becomes the adventure-ready camper of your dreams.
The Conversion Process: More Than Just Following Steps
While we documented our entire Mercedes Vito van conversion in a video series (available throughout this guide – and don’t forget to subscribe to our Youtube channel for more van conversion content!), it’s crucial to understand that van conversion isn’t always linear. Our video format might suggest a stage-by-stage process, but in reality, we often juggled multiple tasks simultaneously. We might start one job, jump to another, and circle back later. If we weren’t creating a video series, we might have approached certain stages, like insulation and wall cladding, in a more integrated way. Keep this in mind as you read through our Mercedes Vito van conversion guide – adapt the process to your own workflow and van.
Stage One: Stripping Out Your Mercedes Vito Van
The first step in any van conversion, and especially important for a Mercedes Vito van that might have seen years of work, is stripping out the interior. Removing the plastic trim and factory interior reveals the true canvas you’re working with. For us, this stage was a reality check. Beneath the surface, we found accumulated dirt and early signs of rust – common in vans of this age. However, the rust was superficial and easily treated with rust converter and paint. Stage one is primarily about cleaning, removing screws, and preparing the van’s shell for its transformation.
What you’ll need:
- Electric drill & a comprehensive set of drill bits – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- De-ruster – https://amzn.to/2PpFLLA / https://amzn.to/2L0MKvK
- Paint brushes
- Metal scourer
- Cleaning cloths
Alt text: Stripped interior of a Mercedes Vito van, showcasing the bare metal ready for camper conversion, highlighting the initial stage of a DIY van build.
Stage Two: Insulating Your Mercedes Vito Van for Comfort
Insulation is paramount for a comfortable camper van, especially if you plan to travel in varying climates. For our Mercedes Vito van conversion, the biggest challenge was choosing the right insulation materials and methods. We explored options at our local DIY store, considering factors like cost, effectiveness, and ease of installation. Ultimately, we opted for a combination of insulation board for the floor, recycled plastic bottle insulation for the walls and ceiling, and reflective bubble insulation as a vapor barrier.
While we insulated the floor of our Vito van with insulation board for added thermal and sound insulation, in hindsight, it might be unnecessary, particularly if you’re installing carpet flooring. If you do insulate the floor, choose solid insulation boards over polystyrene for better durability. Recycled plastic bottle insulation stood out as an excellent choice due to its rot-proof, non-flammable, and user-friendly nature – we highly recommend it for your Mercedes Vito van walls and ceiling. Finally, reflective bubble insulation acts as a crucial vapor barrier, preventing moisture buildup within the van walls and protecting against condensation. We advise installing wall cladding concurrently with insulation to streamline the process. Expandable foam was another option we experimented with but found less practical and wouldn’t recommend for this Mercedes Vito van conversion.
What you’ll need:
- Actual insulation – https://www.diy.com/
- Reflective insulation – https://www.diy.com/
- Insulation boards – https://www.diy.com/
- Insulation tape – https://amzn.to/2vkDbx8 / https://amzn.to/2PpFQim
- Spray adhesive
Stage Three: Flooring in Your Mercedes Vito Van Conversion
With the insulation in place, the next step in our Mercedes Vito van conversion was the flooring. After removing the original rubber floor mat in our Vito, we noticed four troughs or grooves running along the van’s base. These were perfectly positioned to house 34x34mm timber lengths, with our insulation boards fitting snugly in between.
We secured the timber into the Vito van floor using self-tapping screws. Alternatively, a strong silicon adhesive could be used if you prefer to avoid drilling into the van floor. Next, we laid down MDF flooring on top. Due to material availability, we used multiple smaller sheets (6mm x 610mm x 1220mm), but larger sheets would have resulted in fewer joins and gaps for a cleaner finish in your Mercedes Vito van. A key skill at this stage is learning to ‘scribe’ around the wheel arches for a seamless floor fit. While difficult to explain in text, numerous video tutorials online demonstrate this technique effectively.
What you’ll need:
- 34mm x 34mm x 2.4m timber – https://www.diy.com/
- 6mm x 610mm x 1220mm MDF – https://www.diy.com/
- 50mm self tapping screws – https://ebay.to/2EKykcH
- 20-30mm regular timber screws
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Jigsaw – https://amzn.to/2PyRUxX
Stage Four: Cladding the Walls of Your Mercedes Vito Van
Moving onto the walls of our Mercedes Vito van, we knew we preferred the aesthetic of cladded walls over plain plywood or MDF. If you share this preference, your main cladding options are tongue and groove wood or repurposed pallet wood. We chose pallet wood for our Vito van conversion to save money and embrace a more sustainable approach. However, we didn’t initially consider if the added weight of pallet wood would impact fuel efficiency over time – the actual difference in weight is debatable. To optimize material use, we used MDF to clad wall sections that would be concealed behind cabinets, effectively doubling it as cabinet backing.
What you’ll need:
- Pallet wood
- Two sheets of 6mm x 610mm x 1220mm MDF – https://www.diy.com/
- 25-30mm self tapping screws – https://ebay.to/2EKykcH
- White paint – https://amzn.to/2PtAYIX / https://amzn.to/2vi28t5
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Hand saw / jigsaw – https://amzn.to/2PyRUxX
Stage Five: Roof and Lighting for Your Vito Van Camper
The roof cladding process in our Mercedes Vito van conversion mirrored the wall cladding, but with the added complexity of limited screw points to avoid penetrating the van’s exterior roof. Our Vito van roof had two structural ridges we could safely screw into. However, locating these ridges after covering them with reflective insulation was challenging. A better approach might be to first screw timber pieces (around 20mm thick) into the ridges, then attach the pallet wood to these timbers – simplifying the process considerably. Before cladding the roof, consider your lighting plan. Our lights were designed to screw directly into the wood, with wiring routed through holes behind the cladding to a connection box (electrical details will be covered in a separate video).
What you’ll need:
- Pallet wood
- 25-30mm self tapping screws – https://ebay.to/2EKykcH
- White paint – https://amzn.to/2PtAYIX / https://amzn.to/2vi28t5
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Hand saw / jig saw – https://amzn.to/2PyRUxX
- Lights – https://ebay.to/2GYCRfk
Stage Six: Trim Work to Finish Your Mercedes Vito Van Interior
At this stage of our Mercedes Vito van conversion, we focused on refining the interior and addressing areas where walls met the roof and exposed metal framing remained visible. We used leftover pallet wood to extend the wall cladding around to the rear doors – a surprisingly time-consuming task. For the wall-roof joints, we opted for 3mm thin hardboard, which provided a much cleaner finish than thicker pallet wood. Another challenge was trimming above the sliding doors and where the roof met the cab area. Our solution was to use more pallet wood to box in any exposed metal sections. Precise instructions for this stage are difficult as it largely involved improvising and problem-solving as we progressed – hence its absence from our video series!
What you’ll need:
- Pallet wood
- 3mm hardboard – https://www.diy.com/
- A selection of regular timber screws
- 25-30mm self tapping screws – https://ebay.to/2EKykcH
- White paint – https://amzn.to/2PtAYIX / https://amzn.to/2vi28t5
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Hand saw / jigsaw – https://amzn.to/2PyRUxX
Stage Seven: Chalkboard Back Doors – A Unique Feature for Your Vito Camper
For the rear doors of our Mercedes Vito van, our initial plan was simple plywood sheets. However, the doors’ curvature made this impractical. Our second idea, and final execution, involved using pallet wood for the lower halves and plywood for the curvier upper sections. This required creating cardboard templates, tracing them onto plywood, cutting the shapes, spray painting them black chalkboard paint, and finally screwing them onto the doors. While not our most polished work, these chalkboard doors add a unique, functional feature to our Vito van, doubling as message boards or creative spaces. Insulating these large surface areas was essential; otherwise, we might have retained the original plastic trim, as we did with the sliding side doors.
What you’ll need:
- Pallet wood
- 5mm plywood – https://www.diy.com/
- 25-30mm self tapping screws – https://ebay.to/2EKykcH
- Black chalkboard spray paint – https://amzn.to/2Ds0Ik8
- White paint – https://amzn.to/2PtAYIX / https://amzn.to/2vi28t5
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Hand saw / jigsaw – https://amzn.to/2PyRUxX
Stage Eight: Building a Cab Wall in Your Mercedes Vito Van
The primary function of the cab wall in our Mercedes Vito van conversion was to serve as the back of our wardrobe unit, positioned directly behind the driver and passenger seats. Ideally, with a slightly larger budget, we would have added reflective bubble insulation to this wall for enhanced thermal performance. However, this remains a potential future upgrade. For the wall itself, we used MDF sheets. Attaching it securely to the Vito van frame proved somewhat complex. We had to trim some plastic trim to expose the metal frame, to which we screwed 18x44mm timber pieces. Then, using existing threaded holes, we bolted a 34x34mm timber piece to a metal section running widthwise under the front seats. These timber supports provided adequate alignment and a solid base to screw the MDF cab wall into place.
What you’ll need:
- 6mm x 610mm x 1220mm MDF – https://www.diy.com/
- 34mm x 34mm x 2.4m timber – https://www.diy.com/
- 18mm x 44mm x 2.4m timber – https://www.diy.com/
- 6mm x 40mm bolts
- A selection of regular timber screws
- 25-30mm self tapping screws – https://ebay.to/2EKykcH
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Hand saw / jigsaw – https://amzn.to/2PyRUxX
Stage Nine: Pull-Out Bed and Wardrobe Unit for Van Life
Our unit construction in the Mercedes Vito van is straightforward, prioritizing functionality and stability over complex designs. The highlight is the pull-out bed featuring an alternating slat system. Every other slat is mounted to a separate piece of wood, enabling the bed to double in width when extended. Furthermore, we designed hinged bed slats. Instead of directly screwing slats to the bed frame, we first attached a layer of 18x44mm timber, hinging every other slat to this layer.
The wardrobe unit, placed against the cab wall, is integrated into the bed structure, sharing framing to maximize space and material efficiency in our Mercedes Vito van conversion. The wardrobe build isn’t extensively featured in our video series due to a varnish mishap that required rework. The countertop uses 18x70mm timber offcuts from the kitchen worktop, and the shelf is a 6mm MDF sheet, supported by the unit’s frame and L-brackets. Considering our desire to finalize this stage, the outcome is remarkably functional and aesthetically pleasing.
What you’ll need:
- Unit Sides – 3mm hardboard – https://www.diy.com/
- Structure – 34mm x 34mm x 2.4m timber – https://www.diy.com/
- Bed Slats – 18mm x 44mm x 2.4m timber – https://www.diy.com/
- Wardrobe Top – 18mm x 70mm x 2.4m timber – https://www.diy.com/
- A selection of regular timber screws
- Grey paint – https://www.homebase.co.uk/
- White paint – https://amzn.to/2PtAYIX / https://amzn.to/2vi28t5
- Varnish – https://amzn.to/2PscEqX / https://amzn.to/2PsvFcC
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Electric sander – https://amzn.to/2ZvInMA
- Hand saw / jigsaw – https://amzn.to/2PyRUxX
Stage Ten: Installing a Functional Kitchen in Your Mercedes Vito Camper
For our Mercedes Vito van conversion kitchen, we maintained a consistent aesthetic with the wardrobe and bed units. We painted the structure white, side panels grey, and applied a dark walnut varnish to the kitchen worktop. Regrettably, the kitchen build isn’t prominently featured in our video series. A key element of our kitchen setup is the quality components we sourced (linked below). For the sink, we used a jigsaw to cut a hole in the worktop, ensuring the diameter was slightly smaller than the sink to prevent it from falling through. Initially, we considered applying silicon around the sink, but it proved unnecessary.
Installing the tap was straightforward, requiring only a hole drilled no larger than 20mm. Wiring the tap to the battery and water pump is part of the electrical system installation – detailed in our dedicated electrics video. To complete the kitchen, we chose a two-burner cooker that uses small butane canisters, avoiding the need for a large gas bottle and associated drop vent installation in the Vito van floor. We are extremely satisfied with its performance and convenience.
What you’ll need:
- Unit Sides – 3mm hardboard – https://www.diy.com/
- Structure – 34mm x 34mm x 2.4m timber – https://www.diy.com/
- Kitchen Top – 18mm x 70mm x 2.4m timber – https://www.diy.com/
- Shelf – 6mm x 610mm x 1220mm MDF – https://www.diy.com/
- A selection of regular timber screws
- Grey paint – https://www.homebase.co.uk/
- White paint – https://amzn.to/2PtAYIX / https://amzn.to/2vi28t5
- Varnish – https://amzn.to/2XJOY4W / https://amzn.to/2XJ2ohG
- Electric drill – https://amzn.to/2Vk9Zot / https://amzn.to/2Ptlu7N
- Hand saw / jigsaw – https://amzn.to/2PyRUxX
- Sink – https://ebay.to/2kl50n0
- Tap – https://ebay.to/2VuLSQr
- Pump – https://ebay.to/2EIp3Dw
- Hose – https://ebay.to/2Xw4tNS
- Containers – https://ebay.to/2NElssE
- Cooker – https://ebay.to/2moxcGn
- Battery – https://amzn.to/2XwN470
Alt text: Interior view of a Mercedes Vito van conversion, focusing on the newly installed kitchen unit with a sink and two-burner cooker, showcasing the functional kitchen setup in a DIY camper.
Ready to Convert Your Own Mercedes Vito Van?
We hope this guide inspires and equips you for your own Mercedes Vito van conversion project. Remember, DIY van conversion is a journey of learning and adaptation. Don’t be afraid to deviate from our steps, experiment, and tailor your build to your specific needs and the unique characteristics of your Mercedes Vito van. If you found this blog post helpful, leave a comment below and share your own Mercedes Vito van conversion experiences! Don’t forget to subscribe to our Youtube channel for more van conversion videos and travel inspiration. Happy building!
