Self Build Guide - 2. Workspace and Tools

This is part of our self-build caravan series. This section covers the workspace and tools you need before the build starts.

The big trap is underestimating space. You need room for the chassis, the finished caravan height, long sheets, wall frames, roof sections, tools, clamps, ladders and safe access around the job. If the workspace is too tight, every stage takes longer.

For the full series, start with Ever Wanted To Build or Rebuild a Caravan?.

1. Workspace requirements

The minimum space required to build a caravan is about 3.5m wide, the length of the caravan including the A-frame, plus an extra metre. If you are building in the minimum space, you may need to construct walls, ceiling panels and furniture modules on the caravan floor.

The height needs to be about 3m to 3.5m, including rooftop air conditioning on an off-road caravan.

As a guide, a 6m (20ft) caravan needs a minimum working space of about 8m x 3.5m, and the garage door must be big enough to get the completed van out.

More space is better. Being able to build walls and furniture beside the chassis is preferable because you can add mudguards and floor coverings before making the walls.

Some people have built entire caravans outside, but this involves a lot of time adding and removing tarps. It also makes it harder to keep timber, ply, wiring, glue and sealants dry and clean.

2. Essential tools

Without detailing every tool that most sheds already include, the following will also be needed:

• Portable belt sander.
• Oscillating multi-tool, such as a Renovator-style tool.
• Air compressor with staple gun or guns.
• Angle grinder with alloy cutting wheels.
• Heat-shrink gun.
• Router.
• Timber drop saw.
• Left and right offset tin snips.
• Clamps.
• Set square and level.

If you are building your own chassis, you will also require:

• Arc or MIG welder.
• Angle grinder.
• Metal drop saw.

3. Useful extra tools

The following are not essential, but make the building easier and more accurate:

• Air-operated pop rivet gun, or a manual pop rivet tool.
• Electric sheet metal nibbler.
• Bench saw to trim timber profiles.
• Dust extractor for sawdust.
• Soldering iron for approved low-voltage electrical connections.
• Bench sander.
• Bench grinder.

Some of these tools may only save time on one or two jobs, so it can be cheaper to borrow, hire or outsource that step.

4. Rarely used or outsourced tools

If you want to make a sheet metal front boot liner, water tank protectors or your own mudguards, you may need a sheet metal bender.

If this is the only time you would use one, the work can often be outsourced or made with flat sheets joined at the corners. Some DIY samples can also be found on YouTube.

The important thing is not to buy every possible tool at the start. Work out which tools are needed repeatedly, which can be hired, and which jobs are better handled by a specialist.