Wondering how to start your van conversion? Follow this order: planning, cutting openings, insulation, electrical rough-in, walls and flooring, plumbing, then cabinetry and testing. Skipping a step or doing things out of order can be costly to fix once the panels are installed.
At Vanlife by Canada RV, we regularly see DIY projects that have to be partially taken apart because a step was done too early or too late. Here’s the order our technicians recommend, and why each step matters.
Where Should You Start Before Cutting Into Your Van?
Before picking up a tool, set your budget, decide how you’ll use your van (weekend trips or full-time vanlife), and take all your measurements. Check your insurer’s requirements for vehicle modifications, too.
Once you’ve set your budget, sketch a basic layout showing where the bed, kitchen, windows and vents will go. This plan will guide every step that follows, so take the time to confirm it before reaching for the saw. Many vanlifers tackling their own conversions skip this step and end up redesigning things mid-build, wasting both time and materials.
Should You Cut Openings for Windows and Vents Before Insulating?
Yes. Cut openings for windows, roof vents and exterior cable pass-throughs while the van’s sheet metal is still exposed, before insulation and interior panels get in the way.
Cutting openings after installing insulation means going through multiple layers of material, increasing the risk of damaging work you’ve already completed. This is also the time to install roof vents and properly seal every opening. Poor sealing here can cause water leaks that may not become apparent until a year later.
In What Order Should You Insulate the Floor, Walls and Ceiling?
Several insulation materials work well. 3M™ Thinsulate is an established industry choice thanks to its light weight and moisture resistance. Our technicians also offer Soliège spray cork insulation, a natural, durable option for which Vanlife by Canada RV is the Canadian distributor. The right choice depends on your budget, access to the van’s tight spaces, and whether you plan to install it yourself or have someone do it. We explore the options in detail in our article, Van Insulation: What Should You Choose?
What Are Furring Strips, and Why Are They Installed After Insulation?
Furring involves installing strips over insulated surfaces to level them and create a solid base for attaching wall panels and flooring. It comes immediately after insulation, before any other interior framing work.
Unlike a conventionally framed house, a van has almost no flat surfaces or right angles. Furring compensates for these uneven surfaces, creating an even, secure base for wall panels and flooring. Skipping this step or doing it poorly can lead to bulging walls or a floor that shifts once the cabinets are installed.
Does the Electrical Rough-In Come Before or After Insulation?
Electrical wiring goes in after insulation and furring, once the cork, Thinsulate and furring strips are in place, but before the walls are closed up. Once the wall panels are installed, fixing or adding a wire becomes a major headache and often means removing an entire section.
That’s why our technicians test every circuit before installing wall panels, never afterward. If electrical work isn’t your strength, this is where professional help really pays off, even if it’s just to confirm the correct wire gauge and grounding.
When Should You Install Finished Flooring and Plumbing?
Finished flooring (vinyl, cork or laminate) goes in after insulation and furring, just before the walls are installed, not at the very end of the build. It extends underneath the walls and each built-in unit, providing a solid base. Plumbing is roughed in alongside the electrical work, before the walls are closed up.
The water tank, pump and fittings should all be checked for leaks before anything around them is closed in. The same principle applies to electrical work: repairing a leak discovered after the interior is finished costs much more than catching it early. Because flooring is installed early in the build, protect it until the work is complete: cover it and avoid dragging tools or materials across it.
Here Are the 7 Steps:
1. Planning
Before you pick up a single tool, establish your budget and how you’ll actually use the van. Occasional weekend getaways and full-time vanlife call for very different builds. Take all your measurements and sketch a basic layout showing the bed, kitchen, windows and vents. This becomes your reference for every later stage, so it’s worth getting it right before you start.
Many vanlifers who handle their own conversions skip this step and end up reworking their plans mid-build, costing them time and materials. Also check with your insurer about the implications of your modifications. Depending on their scope, some changes require an inspection, and some insurers require systems such as heating or electrical to be installed by a certified professional rather than as DIY work.
2. Cutting Openings
Cut the openings for windows, roof vents and exterior cable pass-throughs while the sheet metal is still exposed, before insulation and panels block access. Cutting through the van after insulation is installed means going through multiple layers of material, with a real risk of damaging work already in place.
This is also when you install the vents and carefully seal every cutout. Poor sealing may not reveal itself until a year later, when water starts leaking in, something far more time-consuming to fix than doing it properly the first time.
3. Insulation
Once all openings are cut, insulate in this order: floor, walls, then ceiling. In Quebec, where winter temperatures regularly drop below −20 °C, your insulation choice matters both for comfort and for reducing condensation inside the van.
3M™ Thinsulate remains an established industry choice for its light weight and moisture resistance. Our technicians also offer Soliège spray cork insulation, for which Vanlife by Canada RV is the Canadian distributor. The right choice depends on your budget, access to hard-to-reach areas of the van, and whether you plan to do the installation yourself or hire someone. We cover the options in more detail in our article, Van Insulation: What Should You Choose?
4. Electrical
Electrical wiring is installed after insulation and furring, once the walls are ready for wiring but before they’re closed up. After the wall panels go on, correcting or adding a wire becomes a major headache, often requiring you to remove an entire section of completed work. That’s why every circuit must be tested before the wall finish is installed, never afterward. If electrical work isn’t your strength, professional help makes a real difference, even just to confirm wire gauge and grounding.
5. Plumbing
Plumbing work happens alongside electrical work, before the walls are closed up. The water tank, pump and all fittings must be checked for leaks before anything around them is enclosed. As with electrical work, fixing a leak discovered after finishing is always more expensive than finding and correcting it early.
6. Finished Flooring and Walls
The final floor covering (vinyl, cork or laminate) is installed after insulation and furring, before the walls and built-in units. This lets the flooring extend beneath the walls and cabinetry, creating a solid base from the outset.
Because the floor is installed early, protect it throughout the rest of the build: cover it, and avoid dragging tools or materials across it. You don’t want to damage it before you’ve even hit the road. The wall panels also go on at this stage, once the electrical and plumbing systems have been tested and approved.
7. Cabinetry and Finishing Touches
The final stage is installing the bed, kitchen, storage and finishing details. It’s often the most satisfying part of the project, the point when the van truly becomes liveable and ready for the road.
What Mistakes Happen Most Often When You Skip a Step?
The first mistake isn’t installing the finished flooring early, quite the opposite. It’s failing to protect it after installation and damaging it during the rest of the build. The second is closing up the walls before fully testing the electrical system.
Unlike a house, a van has almost no right angles or flat surfaces. Measurements and cutouts that look exact on paper often need to be adjusted on-site, which can extend the build if the original layout wasn’t detailed enough.
What’s Next Once You’ve Planned Your Conversion Sequence?
The next step is to review your plan with someone who has completed dozens of van conversions, before buying materials. At Vanlife by Canada RV, some customers do the entire conversion themselves with our guidance, while others leave part or all of the build to us.
If you’d like us to review your plan before you start, or handle a stage you’d rather not tackle yourself (typically bodywork, insulation, furring and upholstery), contact the Vanlife by Canada RV team to talk it through.
Frequently Asked Questions
Can You Do Part of the Conversion Yourself and Leave the Rest to Our Technicians?
Yes. Every project at Vanlife by Canada RV is different. Some customers do everything themselves with our advice, others leave only the electrical work or insulation to us, and some have us manage the entire conversion.
How Long Does a Full Van Conversion Take?
It varies widely depending on the scope of the project and whether you work on it during weekends or full-time. A simple DIY build can take a few weeks, while a complete conversion with advanced plumbing and electrical systems often takes several months when you’re working alone.
What’s the First Thing You Should Buy Before Starting?
Nothing until your layout and final budget are ready. Buying supplies before you know your exact measurements and design is one of the most common ways to waste money on a first build.
Can You Create Custom Plans and Cut Parts for My Conversion?
Yes. Our team can create your plans in-house, and our shop is equipped with a CNC machine that lets us cut custom cabinetry components directly from your plans.