Essential Tools for Van Conversion Projects
Are you considering converting a van into a camper or a mobile office? Van conversions have become increasingly popular in recent years, offering a cost-effective and customizable alternative to traditional RVs. Whether you’re converting a Ford Transit, Ram Promaster, or any other van model, having the right hand and power tools is essential for a successful conversion project.
In this article, we’ll discuss the essential tools you’ll need for your van conversion project, from basic hand tools to specialized equipment.
Basic Hand Tools
Before you start your van conversion, make sure you have a good set of basic hand tools. These tools will come in handy for a variety of tasks, from measuring and cutting to drilling and screwing.
Some essential hand tools to have on hand include:
Image | Tool | Link |
 | Tape Measure | |
 | Level | |
 | Hammer | |
 | Screwdrivers (Phillips and Flathead) | |
 | Pliers | |
 | Utility Knife | |
 | Drill (Entry Level) | |
 | Drill (Professional) | |
 | Drill Bits | |
 | Wrench Set | |
 | Socket Set | |
 | Hack Saw | |
 | Tool Kit (Basic) | |
 | Tool Kit (Advanced) |
Having these tools readily available will save you time and frustration during your conversion project.
Power Tool Brands
While hand tools are essential, power tools can make your conversion project much more efficient.
Budget Brands
When it comes to which power tools to choose, there are many options. If you do not plan to complete future DIY projects, and you’re not a DIY enthusiast, you may be able to get away with buying the well-known budget brands for your camper van conversion, or even the less expensive Chinese knock off brands on Amazon.
The main difference between these brands and the professional brands is their longevity, construction, and power. Some of the budget electric power tools I have listed are corded vs. the cordless lithium ion batteries in the professional tools. The batteries and the batteries charger increases the price of the professional tools.
I had a set of Ryobi tools for many years that I completed DIY jobs with. They lasted through the years, but they didn’t have enough power for heavy-duty projects. Also, I drop my tools a lot, and the Ryobi did not hold up well to drops.
The budget brands are:
Professional Brands
Most of my experience lies with Dewalt power tools, however Makita and Milwaukee are considered to be as good or better than Dewalt. The DeWalt tools are so popular that many Chinese knock off brands make their tools in black and yellow to appear like DeWalt tools.
I am rough on my possessions, and I drop my Dewalt power tools on a regular basis. Sometimes I drop them from the top of the van to the ground. None of them have cracked plastic like my Ryobi tools did. This level of robust construction is very important to me.
Dewalt power tools are also powerful enough to handle any camper van conversion job fast. So, I recommend the Dewalt tools to everyone. The professional brands are more expensive than the budget brands, which is why I recommend them to people that will use them past their camper van conversion project.
The professional brands are:
For more information on the differences between budget and professional power tools, see Power Tools Comparison: Budget vs Professional.
Essential Van Conversion Power Tools
Here are some power tools that will come in handy during your van conversion:
Circular Saw
A circular saw is a versatile tool that can be used for cutting a variety of materials including wood, metal, plastic, and others. It’s perfect for cutting large pieces of plywood or other materials for your van conversion.
- Budget: Skil 5080-01 13-Amp 7-1/4″ Circular Saw
- Professional: DEWALT 20V MAX Circular Saw, 6-1/2-Inch
In my camper van conversion, I’ve used my DeWalt circular saw for many cutting applications. I like that I can bring the circular saw anywhere to cut, like when I’m on a ladder working on the roof. I only use my larger table saw or miter saw for materials that the circular saw, jigsaw, and reciprocating saw cannot cut.
- Aluminum Extrusion
- Aluminum Bars
- PVC
- Wood
- Plastic
Jigsaw
A jigsaw is a must-have for any van conversion project. It’s perfect for cutting curves and intricate shapes, making it ideal for cutting holes for windows and vents.
- Budget: SKIL 5 Amp Corded Jig Saw
- Professional: DEWALT 20V MAX XR Jig Saw
I’m not a big fan of using the jig saw for anything but wood. When I use it on metal or plastic, the jig saw blades tend to break, and I find my reciprocating saw or grinder to be easier to use. Getting the jig saw blade into the cutting channel, and keeping it there, can be challenging. However, for cutting wood it is one of the only tools that will give you precise non-straight cuts.
Power Drill
A power drill is an essential tool for any construction project, and a van conversion is no exception. It will come in handy for drilling holes and driving screws.
- Budget: SKIL PWR CORE 12 Brushless Motor 12V 1/2 In. Drill
- Professional: DEWALT 20V MAX XR Cordless Drill/Driver, 1/2-in
I use my DeWalt power drill nearly every day that I’m working my van. I’ve dropped it on the ground many times and it just keeps on going. It can drill through most anything I put in its way. Only with thicker metal do I have to put away my DeWalt drill and get out my hammer drill.
Impact Driver
An impact driver is a powerful and versatile power tool used in construction and DIY projects. It delivers high torque for driving screws and bolts quickly and efficiently. The impact driver combines rotational force with concussive blows to tackle tough fastening tasks, making it a must-have tool for any project requiring precision and speed.
- Budget: SKIL PWR CORE 12 Brushless 12V 1/4 In. Impact Driver
- Professional: DEWALT 20V MAX XR Impact Driver, Brushless, 1/4″
I definitely use my DeWalt Impact Driver every single day that I work on the van. It is the tool that I use the most by far. Having just a drill is not enough. The impact driver is much better suited for driving screws and bolts in. And you will be often switching back and forth between the drill and the impact driver as you drill holes and then drive a screw into them.
Angle Grinder
An angle grinder is a powerful tool that can be used for cutting, grinding, and polishing. It’s perfect for cutting metal and smoothing rough edges.
- Budget: SKIL 9295-01 6.0 Amp 4-1/2-Inch Angle Grinder
- Professional: DEWALT DCG412B 20V MAX Angle Grinder, 4-1/2”
The grinder is one of my favorite tools because of it’s versatility. It can cut through anything including thick metal. It’s small enough to get into tight spaces, and it’s lack of a true safety guard makes it fast and convenient to use.
However, that also makes it one of the more dangerous tools to use and you can easily cut a finger off. I have hit myself before and it cuts skin like a hot knife through butter. It also sprays copious sparks and shards when cutting metal, so definitely use gloves and eye protection.
The grinder is my primary cutting tool because it’s small, light weight, and it cuts through material fast.
Specialty Tools
In addition to basic hand tools and power tools, there are some specialty tools that can make your van conversion project easier and more efficient.
Rivet Gun
A rivet gun is a must-have for any van conversion project. It’s used to install rivets, which are essential for securing metal panels and other materials in your van.
- Hand Riveter: Dewalt Heavy Duty Swivel Head Riveter
- Electric Rivet Tool: DEWALT 20V MAX XR Cordless Rivet Tool
An electric rivet tool is relatively expensive compared to the power tools listed above. For that reason, I elected to go with a hand riveter that I used for attaching steel sheets to the roof of my van. Using the hand riveter is a lot of work that is hard on your hands and time consuming. However, I was not sure if I would be riveting anything in the future, so I decided against buying the $260 DeWalt Rivet Tool.
Heat Gun
A heat gun is a versatile tool that can be used for a variety of tasks, from stripping paint to bending plastic. It’s perfect for shaping materials for your van conversion.
- Budget: Stanley BLACK+DECKER Heat Gun, Corded
- Professional: DEWALT 20V MAX Heat Gun
A heat gun is necessary for wiring your van electrical system. It is used for solder seal connectors that join two wires together. I’ve also used it for installing the Kilmat sound deadening panels inside my van.
Air Compressor and Nail Guns
An air compressor is a handy tool to have for any van conversion project. It can power pneumatic tools, such as nail guns and impact wrenches, making it easier to install cabinets and other fixtures in your van.
- Professional: BOSTITCH Air Compressor Combo Kit, 3-Tool
The is one of the non-DeWalt Power Tools that I have. I bought a DeWalt compressor and I was not satisfied with it, so I returned it and bought this Bostitch compressor and nail gun set that works great.
When I’m working with wood, I prefer to use the nail guns instead of screws and bolts. Nail guns are much faster than drilling holes and driving screws into wood.
Safety Equipment
Safety should always be a top priority when working on any construction project, and a van conversion is no exception. Here are some essential safety equipment to have on hand:
Safety Glasses
Safety glasses are a must-have when working with power tools. They protect your eyes from flying debris and other hazards.
- Safety Glasses: Amazon Basics Safety Glasses (Clear/Black), Anti-Fog
Protecting your eyes is extremely important. I find that I have to do several things to ensure that I wear these while I am working:
- If they fog up, I am less likely to wear them. So I have to buy anti-fog glasses. It’s also impossible to keep them from fogging while wearing my respirator.
- If they become scratched, I am less likely to wear them because I can’t see through them well. So I bought 12 pairs from Amazon to easily discard scratched ones for new ones.
- If they’re not comfortable, I am less likely to wear them. So I’ve tried several types of safety glasses to find ones that are comfortable.
- If I don’t have them on me in my work belt, I am not going to wear them. So I have to make sure they are always in my work belt.
The other day I was cutting aluminum with my miter saw and a piece flew up into my eye while I wasn’t wearing safety glasses. I was lucky that it did not permanently damage my eye, and it was a reminder to always wear my safety glasses.
Respirator
A respirator is a personal protective equipment device designed to protect the wearer from inhaling harmful substances, such as dust, fumes, vapors, and infectious particles. It filters the air you breathe, reducing the risk of respiratory problems and maintaining a safe working environment in environments where air quality may be compromised.
- Budget: 3M Personal Protective Equipment Particulate Respirator 8210
- Professional: 3M Rugged Comfort Quick Latch Half Facepiece Reusable Respirator 6502QL
I’ve used the professional respirator linked above while painting, sanding, and cutting for my van conversion project. I do not like the dust mask style respirators because the straps often break and they can’t get a good seal around my mouth and nose.
The 3M 6502QL has a great quick latch feature that allows you to keep the respirator on but slack the tension so you can breathe freely. I find it is important to use this feature frequently because keeping the mask sealed for long periods of time is damaging to my lungs and throat. This is because your lungs have to work harder to breathe through the filters when you have a good seal around your mouth and nose.
Work Gloves
Work gloves will protect your hands from cuts, scrapes, and other injuries while working on your van conversion.
- Budget: 5-Pair Pack Wells Lamont Nitrile Work Gloves
- Professional: Mechanix Wear: The Original Covert Tactical Work Gloves
I really don’t like wearing gloves, which means my hands are always cut and bleeding. I have never found a glove that gives me anything close to the dexterity that my bare hands have. Since you’re usually working with small items like bolts and screws in the camper van conversion, the gloves really get in the way.
If you don’t like your hands being cut and bleeding, you will have to wear gloves at all times while working on your van. The only time I wear them is when my hands are freezing, while painting, while working with larger items that don’t require dexterity, or when I’m doing something dangerous.
Conclusion
Converting a van into a camper or a mobile office can be a fun and rewarding project. However, it’s essential to have the right tools to ensure a successful conversion. From basic hand tools to specialized equipment, make sure you have everything you need before starting your van conversion project. With the right tools and safety equipment, you’ll be on your way to creating the van of your dreams.