How one can Convert a SUV wagon into an inexpensive and straightforward approach!


UPDATE: We lately created a brand new wagon camper conversion again in Australia utilizing lighter and stronger supplies.

Mitsubishi Montero Sport (aka Mitsubishi Challenger in Australia, Pajero Sport in Europe, Strada G-Wagon in Thailand and Shogun Sport within the UK) camperwagon. In 2015 we spent 4 months touring round Chile and Bolivia.

The journey is a gradual and gradual technique of importing the perfect and / or most fascinating ones on our Fb and Instagram pages.

Delica into a cushty camper utilizing solely fundamental instruments abroad.

Like all good tasks, that's why we've come to count on that it will be a quite simple and sturdy expertise.

We have been pleasantly stunned how purposeful, comfy, sturdy and light-weight our camper conversion was. The body of the chair is resting on high of a automobile.

Hopefully this info may assist different individuals trying to convert their automobile right into a camper for touring and journey. I’ve added notes, however they in all probability is not going to make a lot sense till you really begin constructing it. The photographs provide you with extra of an concept of ​​the way it works and appears.


Enable for 12 hours of labor to design, assemble, end (together with varnishing and sanding) and cleanup.

Mission may be accomplished in in the future with two individuals, a big space to work on, supplies readily available, and the right instruments.


Straightforward. Primary energy instruments and information of the right way to use them are required.


Round $ 300 to $ 350 (AUD), together with the excessive density foam mattress (excluding instruments you might must buy).


  • Drill driver (cordless with clutch ideally suited)
  • Socket wrench set
  • Jigsaw
  • Round noticed
  • Sander or sandpaper
  • Locking pliers


  • 3x 9mm structural plywood sheets (often 1200x1800mm)
  • 1x 800mm size of 40x40mm sq. tubing or wooden (for the legs)
  • 14x heavy responsibility hinges (zinc plated or stainless-steel)
  • 16x nook brackets (zinc plated or stainless-steel beneficial)
  • Countersunk, philips head screws (go for shorter 12 or 15mm ones when becoming a member of the ply)
  • Extensive paintbrush, marine varnish and thinner (for end and safety)
  • 1.2m of 20-30mm broad poly webbing (optionally available – for the rear fold out bench)
  • 50-100mm thick excessive density foam mattress (relying in your weight and choice; 80mm was high quality for us)


Clear the again and measure your space. Take the chance to take away the carpet and provides it a great clear. We subsequently advocate utilizing strips of insulation materials to fill the hole and supply a layer between the naked steel and the picket base.

montero sport camper preparation

Lower a bit of ply to be the bottom. Make the bottom as broad as potential within the wheel arches, and the size must be from the again of the passenger seat (folded up) to the door.

Trace: Make sure you mark and go away an entry in case you have a spare wheel beneath

Measure how excessive you need the body after which reduce out the helps that can separate your gear. The helps needs to be from the again door to the seat.

Trace: Be sure you don’t make the body too tall. Don’t forget to issue within the thickness of the mattress you wish to be utilizing. We advocate 80mm thick excessive density foam.

We used three sections, one in opposition to every wheel arch, and one other within the center (barely offset) to separate our gear.

1 work in progress

Measure up the highest part of ply that wishes to be the mattress base. You possibly can attempt to tweak the curves of the ply to match the inner form of the automobile as intently as potential. Use a jigsaw to tear sections off the within or upholstery. The highest part must be the complete width of the inside.

Trace: You possibly can reduce off the "wings" on both sides and fix with hinges. This can make the highest part narrower when putting in, after which fold out to full width as soon as contained in the automobile. So, in case your automobile shouldn’t be notably lengthy, some individuals discover that they can’t put themselves in a high part as much as 2m lengthy that folds out to full size with the entrance seats rolled ahead and tilted.

1 rear view helped complete the Montero Sport camper conversion

Brackets and shallow, countersunk screws to connect the center helps to the bottom.

Be sure you measure and mark it up first.

The again of the body is properly connected. See if there's any bolts or anchors which you should utilize to safe the bedframe.

1 rear view top on Montero Sport camper

Put the highest part in and examine that all the things matches. Trim and regulate as wanted.

Take away the highest part once more. Mark the place the rear seats needs to be and reduce the highest part. If you're not sleeping, the concept is to separate the highest part into two or three items.

We subsequently advocate to drill out plenty of air holes roughly 30-50mm broad all through the highest part to assist stop moisture and condensation beneath the mattress whereas utilizing it.

attaching hinges inside Montero Sport camper

Lower the highest part into the three or 4 lengths. The items rely upon how lengthy they’re. They’ll clear the plastic and roof whereas folding again (see picture).

Side view of Montero Sport camper conversion

As soon as reduce, put contained in the automobile, examine that the sections are match, after which connect the biggest piece to the underside part utilizing screws and nook brackets. Then connect every part collectively and use hinges. Within the picture you’ll discover that the 2 sections are cut up. That is pointless and the sections will likely be stronger.

Subsequent to make the sections concerning the passenger footwells. We used a inflexible 'T' type body and legs that was connected to the rear field. Nonetheless, that is the usage of the third seat within the again.

1 passenger side of Montero sports camper conversion

As an alternative, I'd advocate utilizing aluminum or picket sq. tubing, round 40x40mm, and attaching beneath the entrance part with hinges in order that they’ll fold out and supply help as wanted, however nonetheless enable the sections to be folded again, relatively than having inflexible entrance body and legs as we did.

Inside of Montero Sport camper wagon conversion

An optionally available additional is used to create a rear fold down desk. We use the rear desk many occasions a day. Be sure you use washers when attaching the straps to forestall tearing of the fabric. Additionally, it's a good suggestion to make use of a self-tapping 'snap fastener' to simply maintain the tabletop in place when folded up.

1 rear view Montero Sport camper wagon conversion

1 rear view complete Montero Sport camper wagon conversion

1 finished Montero Sport camper wagon conversion

Our Montero Sport shouldn’t be an enormous automobile so far as 4WD SUVs go. With a number of tweaks you might additionally use this design with different 5-door, mid-sized wagons and SUVs. You simply want sufficient size (with the entrance seats ahead all the best way) to fold the body out to sleep on.

The design can also be fairly price efficient, so long as you realize the best locations to get good worth, high quality supplies. The conversion prices about $ 350 (AUD) all up, together with the tremendous comfy excessive density foam mattress and some shopping for instruments. Contemplating a personal room at a hostel price round $ 50-70 an evening in Chile, the preliminary outlay is shortly paid for itself. Even in Australia most camp grounds cost round $ 20-40 an evening for 2 individuals.

We've been again in Australia I've been testing a lot of potential camperwagon choices, together with the Subaru Outback and Forester, to make one other camper conversion for brief journeys in a smaller, extra economical automobile.

Lastly, we want to lengthen a 'muchas gracias' to our amigos, Juan and Edu from Grizzly Camp Chile, who helped us out by offering a workshop, instruments and help for the construct. We couldn’t have made it with out their assist. Plus they know the right way to make a imply Chilean-style BBQ!

Montero Sport camper wagon conversion finished

If you’re trying to purchase a automobile and convert it to a camper in Santiago, Chile, then they’re undoubtedly value getting involved with!

Suzi Santiago who promote pre-converted automobiles to vacationers. They assist out with doing paperwork, registration and insurance coverage. We've heard a number of good stories about them, so give them a try to tell us your expertise.


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