Small Off-Road Camper Van Conversion Using Aluminium

[@evslone]

Thomas, you were smart to take precautions against a rear collision. On our first date many years ago my now wife and I were sitting in a restaurant at a window overlooking a busy highway. Outside a van waiting at a stop light was smashed from behind. The damage didn't look severe but the contractor's wife was speared by metal rods he had stored in the rear. An ambulance rushed her to the hospital and we drove the driver. I learned later the wife suffered grave injuries but eventually recovered. Bonus: my date and I knew from that interrupted dinner that we were the sort of people who would gladly sacrifice an evening to help a stranger in his time of need.

[@AliasJimWirth]

Yeah. Who would have thought of that? I can't say I would have. Says a lot about Thomas. Bravo, Thomas.

[@CoroDan]

I built a 3 seat VW T4 Transporter campervan setup years ago & I mounted steel plate behind my daughter's seat to prevent anything going through her seat in the event of an impact.

[@chrisclikks]

Very clean build so far. Also mechanical engineer here and I approve of your changes for safety. Your assumption that the low down bar will cause the frame to bend instead of thrust forward is correct!

[@ThomasHeatonPhoto]

That's reassuring 👍

[@kathyjurgens7153]

We were hoping an engineer would weigh in. Glad you did.

[@a.w.thompson4001]

Thanks for the confirmation!

[@frankfisher99]

This is remarkable. I'm probably one of the few people to have had a Delica written off from a rear ender. A model, on her phone, hit us outside the Trafford Centre in Manchester - we were stationary in traffic. The van went up and forward, we wrote off the 406 in front of us. We had a towbar, and yes, it went down and spread the chassis rails, hence the van was written off. From the outside the only damage was that the rear wheel arches were buckled. We were all fine, the occupants of the car in front were also ok, and she got out of her Vectra without a hair out of place, still on her phone, although her engine was literally touching the windscreen. Cops reckoned she hit us at 40+

[@a.w.thompson4001]

@@frankfisher99 Yikes! Glad you're OK!

[@thecrowfliescrooked]

Man you got some skills! Doesn't matter if it's a van build or photography you're a great storyteller.

[@sroughto]

“Oh yeah, that is as square as my Hasselblad 501cm.” Brilliant. :)

[@computername]

Thomas: Mentions 3D Software 3D Software: Isn't Sketchup Engineer: Hits the like button

[@bburchellphotos]

Damn. Thomas is being all sensible and smart with his camper van. I was kinda hoping he'd go all Top Gear and build a 3 story camper like Jeremy Clarkson did hahaha

[@airdailyx]

Can’t forget the Zen garden! 😂

[@aaroncarr5725]

The best part was watching it go over the cliff while Jezza has no idea.

[@codedresults]

I need to stop watching van build and photography blogs and go out and do both for myself! Thanks for the great walk through, has given me the confidence to possibly attempt this myself.

[@eclectictomboy6873]

You and me both. I’d do it right now if they made a 6 cyl. Awd or 4 wheel drive midsize with a high ground clearance in a midsize and trailhead worthy van available in the USA. Unbelievable. The Sprinters and Transits are too long. Frustrating.

[@lachlankerr7339]

@@eclectictomboy6873 These vans are available in the states, although more common over there is the L300 (earlier model of this van (which is an L400)). Do some research but i think you'll find these L400's become more readily available due to your 25 year import rule. GOod luck mate

[@eclectictomboy6873]

@@lachlankerr7339 Thank you.

[@sarukravitz4981]

I am impressed by not only the thoughtfulness and through approach to your build, but also by the thoughtful comments - so rare on KZbin. What's more, the spelling, the grammar, and the well-expressed thoughts in the comments point to an educated, intelligent following. I suspect they are a reflection of the content of the channel.

[@Luigi13]

Well, I must say the aluminum framing is a lot better than any wood framing I have seen on You-Tube van builds. First of all it is light which saves on weight second it is more flexible to work with as you demonstrated with all the connectors. It is also a clean finish over all. I must admit that you have demonstrated a good workmanship beside photography that will add to your video adventures. I will not be surprised that there will be many others who might get inspired on their own van built to follow your example. Good workmanship, cheers.

[@ThomasHeatonPhoto]

That's very kind, thank you.

[@MarcNosrednug]

Brilliant! The first ever KZbinr who considers safety! WELL DONE!

[@nevillewatkins4997]

I can imagine you rubbing your hands in glee at the thought of the places you are going to go. Must be a great feeling.

[@ThomasHeatonPhoto]

Holding my breath 🤞

[@beargrylles2185]

I dont know Thomas Heaton and nor have i seen his videos but this chap is bloody marvellous! Content excellent, his style is real easy viewing and the end product is great! Well done Thomas Heaton.

[@WhenWillILearn]

The aluminium is such a smart way to go for this project

[@felixcat9318]

Interesting channel owner/presenter/narrator and superb videography makes subscription a must!

[@alangoulden79]

Love it Thomas!!! Though for a man who has (I quote) 'never built anything', you sure do have a well stocked workshop and tool selection!!

[@Rocking_J_Studio]

While you said you hadn't built anything like the van before I have to tell you I'm very impressed with not just the design, but the craftsmanship you brought to the project. Well done!

[@ianj3845]

Really impressed by the thought and planning that’s gone into your project, especially your decision to make changes when confronted with a safety issue. For someone who says they are “no engineer” you can certainly think like one. Looking forward to seeing the rest of the van build.

[@frankbox850]

Finally someone is thinking about crash safety in a van build. Great job.

[@123Coffs]

Nice! I love the aluminum idea vs wood.

[@marcalvarez4890]

Best. Music. Ever. I am constantly hating the crappy unneeded music on videos, but this song...over and over...I feel like I'm in a 1963 hollywood movie. Fantastic. Cheers and Aloha!

[@maryp2747]

This is called 80/20 here in the states and that's what I plan on using when I do my van build. I work in engineering and we use this stuff all the time for fixtures. If you liked playing with legos when you were a kid you'll have a blast with this stuff. We always called it tinker toys for adults.

[@JasperJanssen]

Kinda weird to call it 80/20 when the size he’s using is 4040.

[@brianbilich6137]

Do you have a link for the 80/20

[@maryp2747]

@@brianbilich6137 There are different suppliers. You can do a search to compare prices and the minimum quantity you need to purchase. For work we bought it from grainger. com

[@AliasJimWirth]

Thomas, your engineering skills are way better than you let on. Excellent job all around. Well thought out and well executed.

[@fototripper]

Looks really sharp mate. Grumpton will be green with envy as his interior resembles the forest floor.

[@CED.Dweller]

You’re funny, much better at crafting and fabricating than you initially led the viewer to believe, and an inspiration for a guy who’s thinking of doing a similar build in a 2020 Toyota RAV4. Kudos!

[@Philip8888888]

Interesting material choices. Everybody seems to use wood because it is available/cheap and vinyl flooring as it is waterproof. I'd be interested to see how well the cork floor lasts as I was told it is not so hard wearing.

[@thefrub]

Using the carpet as a template for the floor! That is a clever trick I've never seen before, nice

[@MarkDenneyPhoto]

It's coming together nicely Thomas!

[@opelgang89]

Just like yours, Mark 👍

[@GeorgeLoch]

@@opelgang89 I kind of feel like we are seeing UK vs American style when it comes to these two different builds. We are spoiled with space here in the USA ;)

[@ThomasHeatonPhoto]

Thanks man. Kind of wish I had a Sprinter though.

[@MarkDenneyPhoto]

@@ThomasHeatonPhoto I was actually thinking the same about yours! Seems like your setup will be much more maneuverable than mine. Guess one of each would be the perfect scenario!

[@ian_worth]

I'm thinking about converting my 2010 vauxhall corsa after watching this. 🤣

[@peterrennison465]

Your attention to detail and skill set is excellent Thomas. I like the gas strut safety clamp.

[@daniel635biturbo]

As a engineer, and 15 years into car modification I must say, very nicely done Thomas ! It's good to have concerns about the safety as you had. Try to use the cars original fastening points for seats and seat belts, they are strong and meant to support large loads. Looking forward to the next episode.

[@pat6703]

Thanks for you input. That is good to know!!!

[@1young-geezer]

Damm Thomas - I’m a finish carpenter in southwest USofA, and I’m WHOLLY IMPRESSED! at the job you’ve done from start to finish - so far. ABSOLUTELY looking forward to video 2 of the van build. Miraculous, yes indeed!!! And as usual you are such a fun spokesman for your passions, both camera and saw&hammer (so to speak).

[@g_young_h]

Would love to see a cost breakdown of the frame work.

[@johnlocke7097]

My Im is Pressed, you do realize you have an alternative way of making a living if photography fails.

[@MonkMan693]

Could we have a price breakdown, particularly for the aluminum and its fasteners?

[@VentureVlog]

Yes please

[@petefloydeh7112]

YES .. This.. a breakdown of frame cost.

[@colinsilver8387]

Wow, Thomas is a bona fide craftsman as well as a great photographer. That looked as professional a job as you could get.

[@fotofletch]

Great stuff. I would never have thought about the implications in a rear end shunt. Good work and very neat.

[@jibbajabba4597]

I would have thought that if someone hits you hard enough to shift those bars you've probably got bigger things to worry about than where they'll go but you can never be too safe I guess.

[@storysupport]

REALLY Good call on the break in the Aluminum frame. I AM engineer, turned photographer, and I appreciate this build sir!

[@QuietLightPhoto]

Brilliant! almost as nice as my conversion, lol. Okay, so what I'm going to do Tom is watch all of the videos and then find out what you wish you had done differently. I still want to put a real fireplace in mine as I think the pumps on those heaters are quite loud?

[@wallybeep]

Adam. Today's post of yours is, as always, a genuine pleasure to watch. Fireplace? Great idea! One of those Costco flickering light jobs. Perfect for the next road trip to Vegas. (Horrifying!)

[@QuietLightPhoto]

@@wallybeep yeah a Dickinson Fireplace, my buddy Jeremy has on in his camper, it's awesome.

[@chrisroot7182]

Sorry Adam. I think Thomas has raised the bar on landscape photographer Delica builds!

[@ThomasHeatonPhoto]

I can't wait to see your build. You have the better van, a wood burner would take it to another level. Check out Slim Potatohead's channel. He build a tiny wood stove for his camper.

[@jxmai7687]

make sure you can do BBQ with it.

[@charver1]

Love the camping stove to heat up the brackets for bending. That aluminium looks great. Never seen it used before like that!!

[@Ltmlaine]

”I have never built anything in my life before” 😂 The results really don’t look like it.. Well done!😎👍

[@Scotphotoamateur]

Well done. Almost as skilled a craftsman as photographer. Pleasantly surprised!

[@SarahBurnsStudio]

I always enjoy your videos, and this is obviously quite different, but it was a joy to watch! I appreciate how much time and effort it took to film and edit this! I've watched tons (far too many) van life videos, and you are one of the very few people who spent so much time explaining the planning/design phase, which to me is one of the most interesting parts! Thank you. Looking forward to the rest. Side note: the profiled aluminum is a genius idea! I could see that being useful in my workshop...

[@IvanRiveraStagea]

Beautiful build, Thomas. You're winging it better than many pros.

[@NigelDanson]

Loved this Tom! square as my Hasselblad has to be the best reference ever...

[@username_horse]

Haha yea I liked that reference as well

[@garysearle2091]

Well up to now you have done a brilliant job well done.

[@ACTuber]

This video is a Masterpiece, waiting for the next part.👍

[@joeellis4681]

For a photographer, you’ve got a nice set of power tools! Looking forward to the rest of this build.

[@theindieprojects]

Been waiting for this 🙌

[@TrueHelpTV]

using the carpet as the template is simplistically brilliant and was one of my largest concerns for accidental waste walking into this project. I also hadn't stopped to consider the outcomes of being slammed into from the rear in a wreck, so now I'm engineering breakpoints and considering a metal plate behind my seat.

[@PrimalOutdoors]

It’s looking good, Tom. Jason

[@ChopeZzz]

Thomas, why on Earth watching your videos is so satisfying? 🤓👍👍👍

[@rajtadvi1447]

Haven't even watched the video 😂😂, still know it will be good

[@lucaseytchison2176]

Dude I've been watching this channel since 2016. You're my freaking hero

[@_7cm]

Tom, can you send me a link of where you purchased the framework? I’m on with a similar build - just can’t find 8020 in the UK! Thanks!

[@gary5926]

RS sell a version

[@_7cm]

@@gary5926 thanks, I figured out he used KJN 👍

[@bg45420]

I'm in the USA but I work with Swiss equipment that uses a similar aluminum extrusion called Item. It is very similar to 80-20 with various profiles and fittings. Both are awesome to work with.

[@stacyturner5463]

@@bg45420 I would love to get a link for the products you're talking about here in the US. And can you order them in pre-cut sizes, like he did, to speed the building process along? TIA

[@nomadcompany]

Mate really enjoyed this video for some reason..... for someone who hasn't built anything before what you come up with looks perfect. The colours and the industrial look is spot on.

[@ian-robinson]

At 7:10 I thought I’d tuned into crap gymnastics for beginners. It’s looking good so far.

[@kenbell8752]

Well done Thomas. You have planned and executed this very well!

[@MrExpert]

Lovin it :)

[@paulbarnard5267]

I’m impressed. Not bad van building skills for a photographer. Looking forward to the next instalment

[@pman3384]

Nice job. Can I ask were you ordered the extruded aluminium/ 8020 profile from??

[@User6327]

80/20... perhaps.

[@stevethompson8154]

Your resign of the bed was spot on. The same technology is used in race cars, it is called crumple zones. It does save lives. You made a wise move. It is GOOD idea to wear googles when using a power jig saw (on the cork)

[@1958zed]

It looks like Thomas blew his budget on colorful socks and ran out of money for shoes. Do we need to start a GoFundMe??? 🤣 Great design work and video.

[@J4Photo]

Should I be so fascinated, so mesmerized by this van build? Real everyday guys like me building something complex... yeah...I should be. Your patience (and likely budget) is vastly larger than mine.

[@aaronjeffels]

What do we want? "More voice overs!" When do we want them? "All the time!!!!"

[@johannschopplich]

Thanks for editing that video and not "just" uploading a timelapse. Must've been quite some work. Much appreciated and a joy to watch. :) All the best for the next phase!

[@bpoolmarc]

Hi Thomas - great work there, and definitely gives some more food for thought on our next build :D Did you use 30x30 or 40x40 profile, and what supplier did you use for yours? Thanks! 👍👍

[@vitor.buchli]

I‘m here to ask the same question actually. But since you haven‘t got an answer in a year I don‘t think I will either😂

[@jacobscoville2044]

I made the mistake of ordering 20x20 which he falsely has linked in the video description 😅. Wayyyyy too thin.

[@KellyPettit]

That was fun. You found a new career!

[@keithreed2731]

"A film is never really good unless the camera is an eye in the head of a poet." Orson Welles

[@jennifermedia6288]

I’m so jealous. I would love my own mini van for photo work and to escape. Happy for you mate.

[@bhikhta]

2024 Heaton: I'm selling my 4×4 van because I haven't been using it to its full potential and I've decided to go for a sprinter.

[@codedresults]

2024 Heaton: Petrol/Diesel is too easy for me, I miss too much of the process. I'm selling the 4x4 and getting a horse drawn carriage :)

[@VangelisMatosMedina]

I was looking for this comment, see you all in the future rsrs

[@kodithebear]

Absolutely brilliant install and so clever. Thanks for sharing.

[@ЕвгенийДобрый-ж2с]

4:04 Носочки зачётные! 😂😂😂

[@NoName-t7e]

Love that you chose to use aluminium as I have never been a big fan of using mainly wood in van builds. Seems to me that aesthetically aluminium is more inline with the sort of materials one would expect to see in the construction of a van or truck or car.

[@ChrisTardif_]

Great video Tom. You made the right call not asking the audience to vote on flat vs. a rainy week in the van. I don't think you would have come out on the winning end of that.

[@defcon84]

Now im shure i want the 8020 System in my Volkswagen T5. I was struggling between 8020 and plywood but this looks way more secure for me! Thanks for the video, cant wait so see the rest.

[@GirdHerd]

Thomas, You're smart using 8020 extruded aluminum. It is the perfect material for building frames in mobile vehicles. You may be a novice but your work looks very professional. Humble Roads would be proud.

[@mymai2792]

I love these types of vidz...great tips...& I too am a very enthusistic zero builder. You give me hope. Your rubber flooring & aluminium furnuture is exactly what I'd choose for my 'dream' van. Thank for beaut vid - much appreciated.

[@Bvinodnaidu]

Hi I was watching your video like a short films to understand what exactly you want to do in van You are a professional

[@huwalban]

Thomas, you are living the dream that a lot of us waste time thinking about. Great video and a really interesting start to your build. Looking forward to the next one already. Stay safe sir.

[@bcegerton]

That was a great watch, you really have pushed the bar higher for these build. What’s next? A trailer Hot Tub?

[@earlspiece9403]

Probably been said... your overall design engineering and then the crush consideration adjustments are genius! This clip is a great example of the engineering of how the toes and important safety considerations for any home brew customizations of a van type vehicle. Well done sir!!!! Oh by the way... being an older person, who used to be an Appalachian Trail backpacker, I finally have time to pursue my photog passions and watching your vids are so enjoyable and are helping me fast track the development of my skills... of course the results will be another topic at a later date!. :)

[@TommyDickson]

Very impressed with that Thomas. Seriously tidy job you've done there. Can't wait to see the next video.

[@dianedrake4476]

I love your van. I have the same van without the ladder and i have a two inch lift kit. I want the same conversion. Yours is the very best!

[@madbadger6255]

I've used a sofabed directly behind the front seats, it frees up so much space and is as comfy as your front room. Fit U shape components to the rear and sides. It makes so much sense but people seem to skip over it.

[@TheChromaKid]

I absolutely ADORE this kind of video, thanks for taking on the extra effort of filming the whole process!

[@samarth9341]

Ohhhhhh Cannot wait for the next one and completed van. So that we can start having more of you travelling and content to consume 😋 yayyy!!!! All the best Thomas.

[@kathyjurgens7153]

We're very much enjoying the creative and practical process. Brilliant. Agree completely with one of the comments below: you are a marvelous storyteller.

[@ducaklitschko7810]

This approach to the conversion is just so smart, light weight, easy to build and modify. Love it!!

[@990drifter]

Very excited for you Tom, you're quite the handyman and nearly ready to restart your adventures with your new toy. I'll be watching it progress and love to have something similar, good luck.

[@mettechristineolsen4286]

As someone who normally don't care about cars one bit I really enjoyed this. Also enjoyed the slightly higher tempo and energy! Can't wait to see the next one :D

[@SightseeingStan]

Great van build video Thomas! Can't wait to see what the finished result will look like!

[@pgtips4240]

Maybe you're in the wrong job Thomas, you are making an outstanding job of that van!! I love the materials you ate using. Wow! Can't wait to see what you do next.

[@tomaskonkol8894]

Hi Thomas, great job. Im just looking in you description and you mentioned 8020 profile. For many people that will be misleading as 8020 its not profile size but just brand name. These aluminium extrusion profiles are very common and size what you use looks like 4040. Can't wait for part 2.

[@dmitrybelyakov]

I don't know why it was so satisfying to watch. Good job and great planning!

[@erikswenson2659]

Fantastic stuff. You are truly multi-talented. Glad to see you are trying to be safe. In that vein, I hope you are planning on venting the battery box to the outside.

[@richmilligan5881]

You are a very talented fabricator IMO- that all looks very well planned and executed thus far!

[@ScottymanPhoto]

Absolutely stunning work! Your skills are certainly not limited to just photography. Apparently you’re also quite handy with a tool bag. Truly impressive, Thomas!

[@paulmorris3613]

Excellent, to the point and a good use of modern materials which must keep the weight down.

[@andrewhillphotosvideos2909]

13:47 into the video was a realy clever thought about back inpact... must have played on your mind over night lol. 5' 11inch tall and same thoughts as me lol. Boom!!

[@mp180170]

One point about the aluminium not only is it super strong super lightweight it’s also super expensive!!! Fantastic Build Tom very enjoyable👌🏼

[@zoo2you]

I could watch this all day long. Nicely done.