All prices are in Australian Dollar (AUD)

When I bought the van the back was already somewhat kitted out with a floor, walls and ceiling. There were fibreglass insulation bats in the cavities, a cargo barrier door and also lights + exhaust vents on the roof. Before I could start the van build, I had to remove everything and start from a fresh canvas again.


1. I started by drilling out all the rivets holding in the ply/checkerplate sheets to the walls and ceiling. I ripped off all the sheets to uncover the exposed fibreglass insulation. I grabbed 2 large sized garbage bags and filled them completely. *(Wear gloves, a long sleeve shirt/pants with a breathing mask to avoid being annoyingly ichy and breathing in fibres).

Once all the insulation was removed, I had to scrape away all the glue residue left behind. I ended up using a sanding wheel on a drill and grinder to make this job much easier.

Removing Insulation


2. Next I removed the floor by undoing all the bolts and using a wrecking bar to pry it up. I cut the vinyl flooring along where the ply pieces were butted together to make for an easier removal.

3. Once the floor was removed, I cleaned the floor with warm water and a broom heavily scrubbing to remove all dirt and grime. After it dried I used a grinder with a wire wheel brush to remove any rust build up in the back of the van. I cleaned once more after this, and then put a coat of white rust protector paint on any grinded areas.

Cleaning the van

4. I removed the lights and vents from the roof, which left small holes in the roof. I bought a small off cut of 2mm thick aluminium sheet from a steel fabrication place. Out of this piece I cut about 30 small squares (40x40mm) and 1 large square to cover the holes on the roof and underneath the van (from all the bolts for the floor).

5. Once cut, I filed the edges smooth and then put a coat of the white rust protector paint on. I used clear roof & gutter Sika Flex to adhere the squares to the metal frame of the van. I ran a bead of Sika around the square also for a maximum seal. *(Having a wet finger with a rag to manipulate the Sika Flex makes it a lot easier).

Sika Flex Squares


Sika Flex Under Van


6. I used the medium sanding disk that mounts into a drill to remove rust on the top of the van. I was careful not to go to deep and remove too much paint. Once finished, I used a blower to get rid of any debri on top of the van, followed by spraying the surface off with a hose. I applied white rust protector paint over where I had sanded, and also over the aluminium squares (only on roof, not under the vehicle).

Removing Rust


Now the van is completely stripped out, sealed and protected from rust. Next I will focus on installing sound deader to decrease van body noise. The first stage took me longer than expected, and I think most things will on this project. It will all be worth it in the end!

Van Conversion Sidebar Thumbnail

Travelling East Indonesia Pt. 3 (Mt. Rinjani)

The next adventure was awaiting, Mt. Rinjani! I arrived in Lombok and picked up my bike safe and sound, I didn’t really have a plan so I decided to just stay in Senggigi. While I was there I decided I would climb Mt. Rinjani, so I organised the cheapest price I could...
Read More

5 Common Reasons People Don’t Travel Overseas

To travel or not to travel!? Ummm… TRAVEL! It didn’t take me long to answer that one, to me it’s as simple as 1 + 1. No rocket science here, it's almost a reflex response nowadays. I wouldn’t have always answered this question that quickly however....
Read More

Simple DIY Van to Home Conversion Less Than $350

So you want to live the van life? Here is everything you need to know about converting your van to a home. Converting your van to a simple liveable home on wheels can be done on a tight budget. I converted mine from a standard van to a comfortable home quickly and...
Read More

Travelling East Indonesia pt. 5 (Sumbawa & Flores)

Sumbawa and Flores are large islands located east of Bali in Indonesia. Travelling across them on motorbike takes 8+ hours each, which is exactly what I planned to do across Sumbawa. As I left Sumbawa Besar, I stocked up on petrol and made my way to Lakey’s...
Read More

Travelling East Indonesia Pt. 1 (Lembongan)

After 4 months of living in Jimbaran, I needed a change of scenery, Lembongan! I decided to travel East Indonesia on my 125cc Honda Vario scooter, and take the barges between all the islands. I had a Belgium friend Victoria, who’d I’d met earlier in Bali, she then...
Read More

Travelling East Indonesia Pt. 2 (Gili & Lombok)

Gili Island's here we come! Victoria and I began our journey to Gili Island's. We drove to Padang Bai first, where we jumped on a massive barge travelling to Lembar on Lombok Island. The barge only cost about AU$5 (50.000Rp) each, including the bike. I parked the...
Read More

Camping under the stars at Spring Gully Stays

A quick weekend getaway to escape the busy city grind Every once in a while most people crave an escape from their day to day life. I dream everyday of full time travel, but I am not quite in the position to do that just yet. I set off to meet some other friends at a...
Read More

Bali Indonesia – Ultimate Cheapest Food Guide – 100% Vegan

Are you a budget traveller? Do you prefer to live cheap and travel longer? Are you a vegan? If so then we already have 3 things in common 🙂 I've recently returned to the tropical island of Bali in Indonesia. I've lived in Bali on and off for around 1 year now, and I...
Read More

5 Essential Tips to Do Now, To Travel the World!

It’s no secret, ask most people where they would travel right now if they could go anywhere and you’ll hear a reply like... “Sitting on a white sandy beach in the tropical sun sipping cocktails”. Okay yes, that’s super cliché but you get the point, most likely you’d...
Read More

Vanlife Travel Australia (Byron Bay)

Baton the hatches, check the oil, pack the few belongings you own and lets hit the road to Byron Bay! It’s time to start a new vanlife adventure along the East Coast of Australia, where there’s waves for days and inspiration all around. First stop, Byron Bay! I hug...
Read More