Starting a DIY Caravan Build using composite panels gives you the freedom to design a caravan or RV around exactly what you need. However, building a caravan can be compared to building a small house – there are many different components, systems and requirements to consider.
It is not possible to learn everything in a day. The best approach is to work through your project step by step, do your research and develop a clear design before you start purchasing components or begin construction.
Start planning your DIY Caravan Build
A successful DIY Caravan Build generally follows six basic stages:
- Do your research first – understand what products, materials and options are available.
- Identify what you want – there are many choices to make, so establish your priorities.
- Create your design – consider both the complete project and each individual component.
- Check compliance requirements – ensure everything is compliant and certified where required.
- Cost the project – make sure your proposed build is within your available budget.
- Build what you have designed – once the planning is complete, you can move into construction.
Taking the time to work through these stages before you start building can prevent expensive changes later in the project.
Research and develop your caravan design
Many DIY caravan builders start putting their ideas together by completing some or all of the following tasks:
- Visit local or State Caravan & Camping Shows to get inspiration from the wide range of products available – from complete caravans through to individual appliances and components.
- Draw sketches of your DIY project showing the approximate shape and size of the caravan or RV shell you intend to build.
- Develop a detailed floor plan so you know that all the key items you require will fit inside the available space.
- Engage an appropriately qualified engineer where required to assist with the chassis design and certification or compliance requirements for the completed build.
- Create a basic Bill of Materials listing the main parts and components you intend to use. This allows you to estimate your project cost and check that the proposed build remains within budget.
- Consider where you will build the project, who will be involved and any logistical challenges you may need to manage.
If you are still developing your basic layout, our DIY Caravan Design & Layout ideas guide is a useful place to start.
Create a Bill of Materials
A Bill of Materials is one of the most useful planning documents for a DIY Caravan Build. It provides a central list of the products, materials and components you expect to require.
If you have not created a Bill of Materials before, our templates provide a good starting point. Simply remove the items you do not need and add any additional components required for your particular project.
Download the Draft Bill of Materials – PDF
Download the Draft Bill of Materials – Excel
Your Bill of Materials can then develop alongside the project as your design becomes more detailed.
Design before you start buying components
The design of the project is one of the keys to a successful DIY caravan or RV build.
At DIY Caravans, the customer is usually both the designer and the builder, although they may use a drafter to prepare detailed drawings and engage specialists to assist with particular parts of the construction process.
Knowing what you intend to include and how everything will fit together should ideally be decided before you start purchasing major components. Once construction begins, changing the position, dimensions or specification of one component may affect several other areas of the build.
For example, the position of water tanks can influence chassis design and weight distribution, while the location of appliances can affect cabinetry, electrical wiring, plumbing and ventilation.
Good planning helps these different systems work together rather than having to accommodate them later.
Break your DIY Caravan Build into sections
Most DIY caravan and RV projects can usefully be divided into a number of sections. Each section should be considered in terms of its design, choice of components, construction requirements and how it complements the other parts of the project.
Typical sections include:
- Chassis
- Shell
- External Hardware
- Cabinetry
- Internal Hardware
- Appliances
- Sanitation
- Plumbing
- Electrical – 240V
- Electrical – 12V
- Gas & Compliance
Each of these areas may require different products, suppliers and specialist expertise.
Working through your project using these categories is also a simple way of checking that you have not forgotten an important part of the build.
Building your caravan with Composite Panels
Composite panels are a popular construction method for DIY caravan projects because they allow the walls and roof to form a strong, lightweight and insulated caravan shell.
Using made-to-order products such as our Composite Panel Kits allows the shell to be specified for the requirements of your particular project.
Likewise, components such as Cruisemaster suspension kits can be selected to suit the chassis, intended use and weight requirements of the caravan.
Planning these major components together is important. The chassis, suspension, composite panel shell, floor plan, cabinetry and services ultimately need to function as one complete design.
In our experience, many carefully planned DIY projects can be built to a very high standard. For many builders, creating something specifically around their own requirements is also an important part of the satisfaction of completing a DIY caravan project.
Consider compliance requirements early
Compliance should be considered during the design process rather than after construction has been completed.
Depending on your project, requirements may affect areas including:
- Chassis and structural design
- Dimensions
- Weight ratings
- Braking
- Lighting
- Electrical systems
- Gas installations
- Ventilation
- Identification and registration
Where engineering, certification or licensed work is required, identify this early and involve the appropriate qualified professionals.
This is particularly important when designing the chassis and establishing the required weight ratings for the finished caravan or RV.
For further information about Australian vehicle standards and regulations, visit the Australian Government’s vehicle design and regulation information.
The importance of weight in a DIY Caravan Build
As well as keeping your DIY caravan project within your financial budget, it is equally important to keep it within its weight budget.
Whether you are building a motorhome or a trailer-based project such as a caravan or camper trailer, there will be a maximum permitted mass for the completed vehicle.
For a motor vehicle this may involve its GVM (Gross Vehicle Mass), while a trailer such as a caravan will have an ATM (Aggregate Trailer Mass). The applicable ratings form part of the vehicle’s compliance and identification information.
For more detailed explanations of the terminology, see our guide: What do all the weight terms mean such as GVM & ATM?
For a new build, the required ratings need to be considered as part of the design and engineering process. If you are refurbishing an existing caravan or RV, you need to work within its existing ratings unless an appropriately qualified engineer assesses and approves a change where permitted.
Estimate the finished caravan weight before you build
Every item or component included in your caravan contributes to its finished mass.
This includes larger components such as:
- Chassis and suspension
- Composite panels or other shell materials
- Cabinetry
- Batteries
- Water tanks
- Appliances
- Air conditioner
- Fridge
- Hot water system
However, smaller components, fittings and materials also contribute to the final weight.
You therefore need to estimate the mass in kilograms of the components you intend to use. This will help you estimate the expected tare mass of the finished caravan and determine whether you will have sufficient payload available for everything you intend to carry.
Remember that payload may need to accommodate items such as water, food, clothing, camping equipment and other equipment added after the caravan is completed.
Ultra-lightweight products can sometimes cost more, so weight and cost often need to be considered together when choosing materials and components.
Make sure the different parts work together
A DIY Caravan Build should be considered as one complete system rather than a collection of individual products.
For example, your chassis design should provide suitable locations and routes for water tanks, plumbing and electrical cables. Cabinetry needs to accommodate appliances and services. Heavy components need to be considered in relation to weight distribution, and external hatches and service doors need to correspond with the internal layout.
Thinking about these relationships during the design stage can make construction considerably easier.
It also helps avoid discovering later that a component cannot be installed where originally intended.
From DIY caravan design to construction
Before starting construction, you should ideally have a good understanding of:
- What you want to build
- Your intended use
- Overall dimensions and floor plan
- Chassis and suspension requirements
- Target and maximum weights
- Major appliances and components
- Composite panel and construction requirements
- Electrical and plumbing requirements
- Compliance requirements
- Approximate project cost
- Where the project will be built
- Who will complete specialist work
- The major items required for your Bill of Materials
You do not necessarily need every minor detail resolved before construction starts, but the major elements should work together as part of one overall design.
A little more time spent researching, designing and costing your project at the beginning can save considerable time and expense during the build itself.
For more help developing the initial concept and floor plan for your project, see our DIY Caravan Design & Layout ideas guide.
