How to Convert a Small Van into a Camper for Under €500 (Berlingo, Rifter, Caddy)

You do not need to spend €30,000 on a large van or €6,000 on a prefabricated camper module to enjoy weekends in nature.

Small vans (car-derived models such as the Citroën Berlingo, Peugeot Rifter / Partner, Volkswagen Caddy, Renault Kangoo or Dacia Dokker) are the smartest camper vehicles: they use little fuel, fit in any underground car park, pay normal tolls and let two people sleep comfortably.

In this guide we show you the plan and the exact materials we used to build a complete, modular conversion for under €480 in total.

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1. The Big Secret: Do Not Fix Anything to the Chassis (Zero Re-registration)

The biggest headache for beginners is getting the conversion approved and passing the roadworthiness test (ITV in Spain).

For your conversion to legally count as cargo being carried (and not a major modification of the vehicle), you must follow three basic rules:

1. The module must be removable without fixed tools: It is held in place with ratchet straps attached to the original boot lashing points.
2. Do not alter the seat belts or seat anchor points: If your design folds the rear seats without unbolting them, you keep the legal travel seats.
3. No fixed built-in gas or 230V installations: Everything must be portable and independent.

If you follow these rules, you can remove the kit in under 10 minutes and have a 5-seat car again for your daily commute.

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2. Real Budget and Materials Breakdown

Item	Material / Specification	Estimated Price
Bed frame	15 mm phenolic plywood boards (okoume or birch) cut to size	€115
Screws and hinges	Metal piano hinges (for folding sections) and reinforcement brackets	€28
Custom mattress	30 kg/m³ HR foam (7 cm thick) + removable cover	€145
Thermal insulation	Custom 7-layer window covers with suction cups for every window	€75
Cooking	Portable gas cartridge stove with carry case	€26
Fresh water	12-litre water container with tap and dispenser	€16
Lighting	Warm-light magnetic USB-rechargeable LED lamps (pack of 2)	€22
Tie-down straps	Ratchet straps to fix the module to the boot lashing points	€14
TOTAL	—	€441

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3. Step by Step: Building the Bed Module

Phase 1: Measuring the Boot

The usable standard width between the wheel arches of compact vans ranges from 110 cm to 120 cm. The available length with the rear seats folded down usually reaches 180 cm to 195 cm.

We designed a structure in three hinged sections that open like a book:

• Section 1 (fixed boot base): 115 cm wide x 65 cm deep x 35 cm high (it stays permanently in the boot as a storage chest).
• Sections 2 and 3 (fold forward): Two 115 cm x 60 cm wings that extend over the backs of the folded seats using piano hinges.

Phase 2: Choosing the Board

Do not use chipboard or MDF: they absorb ambient moisture, are far too heavy and crumble over time. The ideal material is 15 mm phenolic plywood made of okoume or poplar, which offers excellent structural strength at half the weight.

Phase 3: Telescopic Support Legs

At the end that overhangs the front seats, we fitted two folding camping-table legs or two reinforced PVC tubes cut to the exact height of the vehicle floor.

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4. The Mattress: Where You Should Never Cut Corners

Sleeping badly ruins any getaway. Many people make the mistake of using inflatable mattresses that end up puncturing or making you cold because of condensation.

The winning combination:

• Thickness: Between 7 and 8 centimetres. Anything thicker reduces the headroom for sitting upright inside.
• Density: At least 28 to 30 kg/m³. Lower-density foam will sink under your hips and you will feel the wooden board.
• Cut into three pieces: Ask the upholsterer to make the mattress in three parts joined by the bottom fabric so you can fold it like an accordion over the boot during the day.

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5. Ventilation and Thermal Blackout Covers

Two people sleeping in such a small space produce around 800 ml of water vapour per night. If you seal the car completely, you will wake up with the windows dripping onto the mattress.

Two essential accessories:

1. Wind deflectors on the front windows: They let you lower the windows 2 centimetres without rain getting in or anyone outside noticing they are open.
2. 7-layer blackout insulating covers: They insulate against cold and heat and block 100% of the light so you do not attract attention or wake up at dawn.

With this basic setup you have covered the essentials of any trip: sleeping soundly, cooking something hot and staying completely independent on the road.