Every van is a little different, and every client wants something specific. This Toyota Hiace 200 Series (4x4) camper fit-out was a good example. We designed and CNC cut the kit for one of our manufacturing partners, DRQ International Imports, who handled assembly and the wider fit-out.
The brief
The clients had a clear list: specific heights, materials and drawer sizes, plus a bunk bed in the back that doubles as a settee. On paper, fitting all of that into a Hiace looked impossible.
How we solved it
- 3D scan of the full interior. We scanned the van with the panel cards removed so we captured every detail of the sub-frame. That meant the design fitted the real vehicle, not a drawing of it.
- A test rig before any cutting. To check the bunk heights the clients wanted, we rigged up a test bunk in the workshop. Once we could feel the space, we knew it would work.
- Fibreglass side pod. We added our fibreglass side pod to give enough room to sleep sideways.
- A sliding upper bunk. When it isn't in use, the bunk slides back and the bottom bunk becomes a settee.
- Custom fibreglass shower base. We CNC cut a one-off shower base from PETG foam and coated it in fibreglass with a flow coat finish, which keeps cost down. The clients rig it up with a curtain.
- 3D-printed details. These included a track for the side sliding doors and a USB outlet bracket in the rear quarter.
The result
We went through several revision rounds with the clients, so the finished van is exactly what they asked for. When it was ready for handover, I tested the upper bunk myself, and it was great. DRQ International Imports did an excellent job on assembly and on customising the rest of the van.
Planning a van or camper build? We can 3D scan your vehicle, design the interior in CAD and CNC cut a kit with assembly instructions. Get in touch.