DIY camper: cargo or window van?

I think it depends on whether you are looking to build a camper, along the lines of the Westfalia and other conversions of the VW vans, with just sleeping space and removable camping gear, or a small motorhome, like most of the B conversions today.

It also depends on whether you have dual use intentions, and what those are. Because I have camping, rather than living in it, intentions, and want five passenger capability converting back to at least eight pasengers, and wiil pull a small TT if I really want to have a house with me, I'm starting with a 18-foot passenger van, won't be taking out much more than seats, and what goes in will all be removable. E-350 this time, because I prefer the passenger arrangements.

If I were wanting to build a small house on wheels, my starting point would be a 20-21 foot (or longer) cargo van, because to get the most space for what goes inside, a passenger van would be stripped to the bare metal walls, and there is a lot of stuff to come out. I would probably look for one with windows in the side and rear doors, so as to have more flexible wall space for installation of RV windows and/or the collection of vents and RV appliances and utilities that mount through the wall. This consideration would likely put me in an Express rather than E-series, as the Express has more contiguous wall space ahead of the rear axle, and less internal wall structure to get in the way. In addition to the bracing I'd have to work around, the Ford has me working with a double-wall construction every place I want to cut.

I think this is why we see more motorhome conversions on extended Express 2500 and 3500, and more camper or dual-use conversions on E-series, but the commercial ones more often start with partially windowed cargo vans than with passenger vans, because all the seating will be custom rather than OEM and they will be doing cabinet work where the passenger van has trim.

Thanks for the reminder about Sportsmobile forums. I had read a couple of their threads -- as unregistered and not able to view pics. I've now registered, and have been pouring over the archive.

Lotta guys there like a window van, often without adding or replacing in-wall insulation. They have noted that window vans are stiffer, due to reinforcements welded around the window frames. And, it's much easier to remove passenger features in a window van than to add passenger features to a cargo van.

Another note was that, if adding vent fan or custom top to a passenger van, the air conditioning air ducting (which appear to be part of the headliner) had to be removed or modified.

And, apparently there's about 6 inches of width below the window line that's wasted by the stock panels in the rear of a passenger wagon. Gaining this space is why some guys choose to remove and re-panel.

Another note I found interesting was about windows in the 60-40 doors: if the van does not come with windows that have (or could have as an option?) the hinged tip-outs, such windows can NOT be added to windowless doors. There's a provision on windowed doors that does not exist on non-windowed doors... thus, any windows added would NOT be hinged tip-out.

Edit: In the interest of making this post as complete as I'm capable, I'm adding a few more things I've learned from continued reading.

1) The passenger vans are more likely to contain "full floating" rear axle assemblies. These axles are better for load carrying, use with wheel spacers, and for general robustness. They can be identified by looking at the rear hubs, where a protrusion beyond the rim of 3-5 inches indicates full floating. Apparently most (all?) E350 wagons through about 2003 had them. And, they were used in some later years, as well. Cargo vans typically had them only when special ordered.

2) If one wants to remove the rear AC unit, the freon/coolant hoses that go to the compressor up front have to be joined with a length of hose in place of the AC unit. This has to be done by a qualified shop, at a cost of $200 or so. They capture the coolant, install the hose, then recharge the AC system.

stan909 wrote:
Although I love this forum,there are better places for DIY questions.sportsmobileforum. com has a groundup build section and cheaprvliving.com is all DIY. Getting to your question re panel vs window. Adding Windows later is expensive but insulating unused windows is cheap and easy.retired hotel and medical transport vans are plentiful( at least here in SoCal)and since they already have the high top that wil save you big bucks.

I have an '89 E-150 window cargo van with the 300 cu. in. 6, and 5 speed stick. It was my daily ride, and I used it some doing furnace work.
It's NOT for sale.

I went with a hightop conversion van (2002 Dodge Ram Van with small block V8). Since I was going to do so many mods to the interior, I wasn't really concerned with resale value and was lucky enough to find a well running unit with an R title. The sliding windows in the conversion van are nice for ventilation. Window blinds will give you privacy. Too bad you live so far south, I bought a TT and a new Van this winter so my old Dodge will be put up on Craigs list later this spring.

Back in the 60's Window Vans were popular. We had one it was a DIY.
Bought the Dodge van brand new. When I ordered it. Only had front seats and one rear bench seat.
Wife made drapes for the windows. I put plywood floor down with carpet.
I also out foam insulation in the walls and paneled them.
I had a rear engine heater for the kids when on the road. A wall folding cot. We traveled all over with it.

I like the passenger van for the extra visibility. I find that the windows have sufficient tinting that you don't have privacy issues during the day (at night you do need to turn off the interior lights to disrobe, etc.). Replacing one of the dome lights with a large LED unit is advisable to save the battery at night, but you really need to run it off of a separate power source then. Since I added a 12v power port in the rear this wasn't an issue (tapped into 12v constant to trailer plug).

After looking at the posts for another DIY project I will have to revise my earlier post. Lots of good ideas here.

Although I love this forum,there are better places for DIY questions.sportsmobileforum. com has a groundup build section and cheaprvliving.com is all DIY. Getting to your question re panel vs window. Adding Windows later is expensive but insulating unused windows is cheap and easy.retired hotel and medical transport vans are plentiful( at least here in SoCal)and since they already have the high top that wil save you big bucks.