I’ve built four campervans with tools ranging from a few quid to several hundred. I’m lucky enough to have most tools I’d ever need, but for those of you that are new to van conversions, hopefully this guide on Essential Tools And Materials For Campervan Conversions will give you a good starting point.
After 30 years as a maintenance manager, you’d think I’d know how to do it all. And for building maintenance, I do. But van conversions are different. The tools you need, the materials that work, and the techniques that matter are specific to working in a cramped metal box with curves, ribs, and awkward angles.
This guide is everything I’ve learned about tools and materials across four builds. Not what the marketing says you need. Not what professional converters use (they have different priorities). What you actually need for a DIY conversion that’ll work properly and last.
The Honest Cost Reality
Let me start with the uncomfortable truth: tools cost money. Good tools cost more money. And you need more tools than you think.
But here’s the thing: those tools have also built two garden sheds, countless furniture pieces, home repairs, and helped three mates with their conversions. Cost per project is actually reasonable.
If you’re building one van and starting from scratch:
- Minimum viable toolkit: £280-£400
- Comfortable toolkit: £600-£850
- Professional-grade toolkit: £1,200-£1,800
You can reduce this by borrowing, buying second-hand, or choosing budget brands strategically. I’ll tell you where to save and where not to.
Power Tools: What You Actually Need
I’m going to be brutally honest about each tool. Some you need. Some are nice to have. Some are complete wastes of money for van building.
Cordless Drill/Driver (ABSOLUTELY ESSENTIAL)
What it does: Drilling holes, driving screws, mixing paint/adhesive
Why you need it: You’ll use this constantly. Hundreds of screws. Dozens of holes. Every single day of the build.
Budget option (£45-£80):
- Ryobi ONE+ 18V
- Bosch Universal 18V
- Worx 20V
These will do the job. Just. The batteries don’t last long. The chuck can be wobbly. But for one van build, they’re adequate.
My recommendation (£100-£180):
- Makita DHP485 18V (£125 for tool + 2 batteries + charger)
- DeWalt DCD796 18V (£140 for kit)
- Milwaukee M18 (£155 for kit)
Why spend more? Battery life (you’re not stopping every 20 minutes). Power (actually drills through metal easily). Reliability (doesn’t strip screws or slip). Warranty (they’ll actually honor it).
Premium option (£200-£350):
- Festool
- Hilti
- Milwaukee M18 Fuel
Unless you’re a professional or doing multiple conversions, don’t bother. Diminishing returns.
What I use: Makita DHP485. Had it 8 years. Built four vans, two sheds, countless projects. One battery replacement (£45). Zero regrets. Would buy again tomorrow.
Verdict: Buy Makita, DeWalt, or Milwaukee. 18V system. Get the kit with two batteries and charger. Budget £120-£180.
Impact Driver (HIGHLY RECOMMENDED)
What it does: Drives screws (much better than a drill/driver)
Why you need it: Seriously, once you use an impact driver for screws, you’ll wonder how you lived without it. No cam-out. No stripped heads. Just drives screws perfectly every time.
Do you NEED it? Technically no. Practically yes.
Budget option (£50-£90):
- Ryobi ONE+ 18V Impact Driver
- Same battery system as your drill (this matters)
My recommendation (£95-£150):
- Makita DTD154 (£95 bare tool, or £145 with battery/charger)
- DeWalt DCF887 (£110 bare)
- Milwaukee M18 (£120 bare)
Buy “bare tool” if you already have batteries from your drill. Buy the kit if this is your first 18V tool.
What I use: Makita DTD154. Hundreds of screws driven perfectly. Still going strong after 6 years.
Verdict: Buy if budget allows (£95-£150). You’ll thank me when you’re driving your 500th screw and it’s still easy.
Jigsaw (ESSENTIAL)
What it does: Cuts curves, cuts holes (windows, vents, sinks), cuts worktops to size
Why you need it: You’ll cut dozens of curved pieces. Hundreds of cuts total. Can’t do this with any other tool safely.
Budget option (£30-£60):
- Ryobi 18V cordless (£55)
- Bosch PST 700 E corded (£45)
- Erbauer corded (£35 from Screwfix)
These cut. That’s about all I can say. They vibrate a lot. The blade wobbles. Cuts aren’t perfectly square. But they work.
My recommendation (£80-£140):
- Bosch PST 18 LI cordless (£110)
- Makita DJV182 cordless (£125)
- DeWalt DCS334 cordless (£95)
Better blade guidance. Less vibration. Cuts stay square. Variable speed (crucial for different materials). Orbital action (faster cuts in wood).
Premium option (£150-£300):
- Festool PSC 420
- Bosch GST 18V-LI
Only worth it if you’re doing lots of fine woodwork. Overkill for van building.
Blade advice: Buy good blades separately. The blades that come with jigsaws are rubbish. I use:
- Bosch T244D (fast cuts in wood, £8 for pack of 5)
- Bosch T118B (metal cutting, £12 for pack of 5)
- Bosch T101B (clean cuts in ply, £7 for pack of 5)
You’ll go through 15-20 blades in a build. Budget £40-£60 for blades.
Verdict: Buy a £80-£140 jigsaw with good blade guidance. Buy decent blades separately. Don’t cheap out here.
Circular Saw (USEFUL BUT NOT ESSENTIAL)
What it does: Cuts straight lines in sheet materials (ply, worktops)
Why you might need it: Faster than a jigsaw for long straight cuts. More accurate for sheet material.
Why you might not: You can do everything with a jigsaw (just slower).
Van #2: Bought a Makita DSS611 cordless circular saw (£120). Massively faster for cutting ply sheets. Much more accurate.
Budget option (£50-£85):
- Ryobi 18V cordless (£75)
- Evolution corded (£55)
- Erbauer corded (£50)
My recommendation (£100-£160):
- Makita DSS611 18V (£120)
- DeWalt DCS391 18V (£135)
- Milwaukee M18 (£145)
What I use: Makita DSS611. Cuts ply and worktops beautifully. Battery lasts ages. No regrets.
Verdict: Nice to have if budget allows. Not essential if you have a good jigsaw and patience. Buy if you’re cutting lots of sheet material.
Orbital Sander (ESSENTIAL)
What it does: Smooths wood, removes paint, prepares surfaces
Why you need it: You can’t build furniture without sanding. You could sand by hand but your arm will fall off.
Budget option (£25-£45):
- Ryobi 18V cordless (£40)
- Black & Decker corded (£28)
- Erbauer corded (£25)
These work. They’re loud and vibrate a lot. But they sand.
My recommendation (£50-£95):
- Makita DBO180 18V cordless (£75)
- Bosch PSM 200 AES corded (£65)
- DeWalt DCW210 18V cordless (£85)
Less vibration = less fatigue. Better dust collection = healthier lungs. Faster sanding.
What I use: Makita DBO180. Sanded all the furniture in all four vans. Still going. Brilliant tool.
Sandpaper: Buy variety packs (40, 80, 120, 240 grit). You’ll use 30-50 sheets in a build. Budget £25-£35.
Verdict: Essential. Budget £50-£95. Get cordless if you’re on the 18V battery platform already.
Angle Grinder (ONLY IF YOU HAVE METAL WORK)
What it does: Cuts metal, grinds welds, removes rust
Why you might need it: If you have welded shelving or rust to remove.
Why you might not: If your van is clean and you’re not cutting metal, skip it.
I needed it in van #1 (ex-fleet van with welded metal shelving). Didn’t need it in vans #2-4.
Budget option (£25-£45):
- Erbauer 115mm corded (£28)
- Evolution 115mm cordless (£40)
My recommendation (£50-£95):
- Makita DGA504 18V cordless (£90)
- DeWalt DCG405 18V cordless (£85)
What I use: Makita DGA504. Used it extensively in van #1, barely in others. Still works perfectly.
Safety: This is the most dangerous tool in the list. Face shield, gloves, long sleeves mandatory. No exceptions.
Verdict: Only buy if you know you need it. Rent it for a day (£15-£25) if you just need to remove some brackets.
Multi-Tool / Oscillating Tool (USEFUL FOR AWKWARD CUTS)
What it does: Cuts in tight spaces, plunge cuts, detail work
Why it’s useful: Getting into corners. Cutting around ribs. Trimming installed pieces.
Do you need it? Probably not for your first van. Useful but not essential.
Budget option (£30-£60):
- Ryobi 18V cordless (£55)
- Erbauer corded (£35)
My recommendation (£70-£130):
- Makita DTM51 18V cordless (£95)
- Bosch PMF 250 CES (£85)
What I use: Makita DTM51. Brilliant for awkward cuts. Worth having if you’re doing multiple builds.
Verdict: Skip it for your first build unless you spot a specific need. Add it later if you build another van.
What You DON’T Need (Despite What YouTube Says)
Router: Unless you’re making fancy edge profiles, you don’t need this.
Table saw: Way too big for van building. Circular saw or jigsaw does everything you need.
Planer: You’re buying planed timber. You don’t need to plane it again.
Biscuit joiner: Nice for furniture making. Overkill for van builds. Screws and glue work fine.
Nailer: Tried using a pin nailer in van #3. Pins didn’t hold in ply properly near edges. Went back to screws.
Welder: Unless you’re building a custom metal frame, you don’t need to weld anything.
Hand Tools: The Unsexy Essentials
Power tools get the glory. Hand tools do the actual work.
Measuring and Marking (CRITICAL – DON’T SKIP THESE)
Tape measure (£5-£15): Get a good 5m tape (Stanley FatMax, £12). Not the £2.99 ones that break after a week.
Actually buy two. You’ll lose one. I guarantee it.
Laser measure (£25-£85): Not essential but brilliant for measuring long distances and heights. I use a Bosch GLM 30 (£45). Paid for itself in time saved.
Spirit level (£8-£25): Get a decent 60cm level. Vans aren’t level. Furniture must be. I use a Stanley FatMax (£15).
Combination square (£8-£25): For marking 90-degree angles and checking squareness. Essential for furniture. Bahco 400mm (£18) is excellent.
Marking pencils (£3): Buy proper carpenter’s pencils. Buy 10. You’ll lose them all.
Chalk line (£6): For marking long straight lines. Stanley (£6). Simple and useful.
Cutting and Shaping
Handsaw (£12-£28): Even with power saws, you need a handsaw. Stanley FatMax (£15) is fine.
Hacksaw (£8-£18): For cutting metal (battery terminals, brackets, conduit). Bahco 319 (£12).
Files (£15-£30): Set of metal files for cleaning up cuts and deburring. Draper 200mm set (£18).
Craft knife (£3-£8): Stanley FatMax (£5). Buy 100 spare blades (£8). You’ll go through loads.
Rasp or Surform (£8-£18): For shaping wood quickly. Stanley Surform (£12).
Fixing and Fastening
Screwdrivers (£15-£45): Despite having an impact driver, you need hand screwdrivers. Tight spaces. Delicate work.
Wera or Bahco sets (£25-£35 for good set). Get:
- Phillips: PH1, PH2, PH3
- Flathead: 3mm, 5mm, 8mm
- Pozidrive: PZ1, PZ2, PZ3
Socket set (£25-£80): 3/8″ drive socket set (Halfords Advanced, £45). You’ll use this for bolts, nuts, removing van panels.
Adjustable spanner set (£15-£35): Bahco 9031 set (£28). Two adjustable spanners (150mm and 250mm).
Pliers set (£20-£45):
- Combination pliers (Knipex, £18)
- Long nose pliers (£10)
- Side cutters (£12)
Hex key set (£8-£18): Metric and imperial. Wera or Bondhus (£15). Furniture and van panels use hex bolts.
Clamps (ESSENTIAL – BUY MORE THAN YOU THINK):
G-clamps (£4-£8 each): Buy at least 6. I use 8. Quick-grip clamps (£8-£15 each): Buy at least 4. I use 6.
You can never have enough clamps. Gluing, holding pieces while you screw, keeping things square while the glue dries.
Budget £60-£90 for clamps.
Electrical Work Tools
Wire strippers/crimpers (£15-£45): Essential for 12V work. Automatic wire strippers (£18) are brilliant. Ratchet crimpers (£25) make proper crimps.
Multimeter (£15-£45): You MUST have this for electrical work. Testing voltage, continuity, finding faults.
Budget option: Erbauer (£15). Works. Better option: Fluke 115 (£145). Overkill but brilliant. My recommendation: UNI-T UT33D (£22). Accurate, reliable, cheap enough not to cry if you break it.
Wire cutters (£8-£18): Specifically for cable. Side cutters (£12).
Cable strippers (£12-£25): Automatic (£18). So much faster than a knife.
Plumbing Tools
Adjustable wrench (£8-£18): For tightening fittings. Bahco 8″ (£12).
Pipe cutter (£8-£18): For cutting plastic pipe cleanly. Rothenberger (£12).
Hole saw set (£25-£55): For drilling large holes (sink, vents, cables). Erbauer set (£28).
Step drill bit (£12-£28): For drilling clean holes in metal. Erbauer (£18).
Other Essential Hand Tools
Hammers:
- Claw hammer (Stanley, £12)
- Rubber mallet (£8) – for persuading things without damaging them
Pry bar (£8-£18): For removing panels and lifting things. Stanley Wonder Bar (£12).
Utility knife (£5-£12): Heavy-duty (Stanley, £8). Better than craft knife for insulation and thick materials.
Chisel set (£20-£45): For cleaning out corners and adjusting mortises. Bahco 424P set (£28).
Staple gun (£12-£35): For attaching vapor barrier and fabric. Arrow T50 (£22).
Safety Equipment (NOT OPTIONAL)
I’ve been a maintenance manager for 30 years. I’ve seen what happens when people skip safety gear. Don’t be an idiot.
Essential safety gear:
Safety glasses (£3-£12): Buy comfortable ones (£8) or you won’t wear them. Must be impact-rated (EN166).
I use Bolle Safety (£9). Comfortable enough to wear all day.
Dust masks (£8-£25): FFP2 or FFP3 for cutting MDF and sanding. Box of 20 (£15).
Proper mask with replaceable filters (3M 6200, £22 + £15 for filters) if you’re doing lots of work.
Work gloves (£4-£12 per pair): Buy multiple pairs. They get destroyed.
- Light work: Maxiflex (£5/pair)
- Heavy work: Mechanix (£18/pair)
- Cut protection: Aldi special (£4/pair, surprisingly good)
Ear protection (£8-£25): Sanding, grinding, cutting. All loud. You need ear protection.
3M Peltor (£15) – comfortable for all-day wear.
Knee pads (£12-£35): You’ll spend hours on your knees. My knees aren’t great. I use Snickers Craftsmen knee pads (£25). Worth every penny.
Work boots (£40-£85): Steel toe cap. Slip-resistant. I use DeWalt Apprentice (£55). Comfortable and protective.
First aid kit (£15-£35): Plasters, bandages, antiseptic. You will cut yourself. Multiple times.
Fire extinguisher (£20-£35): Keep one near your work area. Especially when working with electrics or gas.
Total safety gear budget: £140-£220
Don’t skip this. Your health is worth more than the saving.
Materials: What You’ll Actually Use
Tools are one thing. Materials are where you’ll spend serious money.
Timber and Sheet Materials
Plywood:
12mm ply (structural): For furniture frames, bed base, subfloors. £25-£35 per 2400mm x 1200mm sheet.
Hardwood ply (birch) is better but expensive (£45-£65/sheet). Softwood ply is fine for most uses.
Budget 6-8 sheets for medium van = £150-£280.
6mm ply (cladding): For wall lining, cupboard panels, doors. £15-£25 per sheet.
Budget 4-6 sheets = £60-£150.
18mm ply (heavy duty): For worktops, bed base if you want extra strength. £30-£45 per sheet.
Budget 1-2 sheets = £30-£90.
What I learned: Van #1: Bought cheapest ply (£18/sheet). It delaminated after 6 months. Had to replace some panels. False economy.
Van #2+: Bought decent hardwood ply (£32/sheet). Still perfect after years. Worth the extra £14/sheet.
Timber (PAR – Planed All Round):
2×2 (47mm x 47mm): For bed frames, structural elements. £4-£6 per 2.4m length. Budget 15-20 lengths = £60-£120.
2×4 (47mm x 100mm): For heavier structural elements if needed. £7-£10 per 2.4m length. Budget 5-8 lengths = £35-£80.
Battens (25mm x 50mm): For wall lining, fixing points. £3-£5 per 2.4m length. Budget 12-15 lengths = £36-£75.
Buy treated timber if possible (extra £1-£2/length). Worth it for moisture resistance.
Worktop:
Kitchen worktop offcut: Solid beech or oak, 28mm thick. Most builders’ merchants have offcut bins. £25-£50 for enough for a van kitchen.
I’ve used beech worktop (£38 for 900mm x 600mm from B&Q) in all four vans. Looks great, durable, easy to work with.
Insulation Materials
Covered in detail in the insulation guide, but budget:
Celotex/Kingspan PIR boards:
- 50mm (roof): £165-£210 (8 sheets)
- 25mm (walls/floor): £95-£145 (6-9 sheets)
Expanding foam:
- Soudal Gap Filler: £6-£8 per can
- Budget 5-7 cans = £30-£56
Vapor barrier:
- Reflectix or bubble foil: £40-£60 for roll
Total insulation: £330-£470
Fixings and Fasteners
You’ll use thousands of screws. Literally thousands.
Wood screws: Buy variety packs. You’ll use:
- 3.5mm x 30mm (general use) – 500 pack (£8)
- 4mm x 40mm (furniture) – 200 pack (£6)
- 4mm x 50mm (structural) – 200 pack (£7)
- 5mm x 60mm (heavy duty) – 100 pack (£6)
Budget £40-£60 for screws.
Self-tapping screws: For fixing into van metal. 4.2mm x 13mm – 200 pack (£8).
Coach bolts: For removable furniture sections. M6 or M8, various lengths. Budget £15-£25.
L-brackets and corner braces: For reinforcing furniture. Various sizes, £1-£3 each. Budget £25-£40 for 15-20 brackets.
Hinges: For cupboard doors. £2-£5 per pair. Budget £20-£35 for 8-10 pairs.
Magnetic catches: For keeping cupboard doors closed. £1-£2 each. Budget £10-£15 for 8-10 catches.
Total fixings: £115-£180
Adhesives and Sealants
PVA wood glue: For furniture joints. Evo-Stik or Gorilla (£8-£12 for large bottle). Budget 2 bottles = £16-£24.
Construction adhesive: For fixing battens and heavy elements. Evo-Stik Serious Stuff or Gorilla Grab (£4-£6 per tube). Budget 4-6 tubes = £16-£36.
Sikaflex 512: For sealing windows and roof vents. £12-£18 per tube (expensive but essential). Budget 2-3 tubes = £24-£54.
Expanding foam: Already mentioned but you’ll use loads.
Silicone sealant: For sinks, worktops, waterproofing. £3-£5 per tube. Budget 3-4 tubes = £9-£20.
Total adhesives: £65-£130
Finishing Materials
Paint:
Primer: For bare wood and metal. £12-£18 per litre. Budget 1L = £12-£18.
Interior paint: Water-based for walls and ceiling. £15-£25 per 2.5L. Budget 2.5L = £15-£25 (white ceiling, grey walls can share).
Varnish/oil: For worktops and exposed wood. Danish oil (£12 per litre) or hard wax oil (£18 per litre). Budget 0.5L = £6-£9.
Total paint: £33-£52
Flooring:
Vinyl click-lock: Waterproof, durable. £25-£35 per pack (covers 2-2.5 square meters). Budget 5-6 packs = £125-£210.
Edge beading: Plastic trim for edges. £8-£15 per length. Budget £15-£25 total.
Total flooring: £140-£235
Electrical Materials
This is extensive. Covered in detail in electrical guide but budget:
Cable:
- Various sizes (1.5mm² to 10mm²)
- Budget £80-£120
Fuse box and fuses: £40-£80
Lights, sockets, switches: £60-£100
Connectors and terminals: £30-£50
Total electrical materials: £210-£350 (not including battery, solar, etc.)
Plumbing Materials
Sink: £35-£80 Tap: £20-£45 Pump: £55-£85 Hose and fittings: £20-£35 Water containers: £35-£60 Waste container: £15-£25
Total plumbing: £180-£330
What To Buy New vs. Used vs. Borrow
After four builds, here’s my strategy:
Always Buy New
Safety equipment: Never compromise. New safety glasses, new gloves, new masks.
Electrical components: Don’t mess with used batteries or electrics. Too risky.
Cutting blades: Cheap and you need sharp ones.
Fasteners and fixings: Not worth buying used. Too fiddly.
Buy Used If Good Condition
Power tools: eBay, Gumtree, Facebook Marketplace are goldmines.
I bought my Makita circular saw used (£75, saved £45). Works perfectly. Check it runs, check battery condition, check blade adjustment.
Hand tools: Spanners, sockets, hammers don’t wear out. Buy used.
Clamps: Quality clamps last forever. Buy used Record or Bessey clamps for half price.
Consider Borrowing
Specialist tools you’ll use once:
- Hole saw set (if a mate has one)
- Angle grinder (if you only need it one day)
- Laser level (nice to have but not essential)
Where I went wrong:
Van #1: Bought an oscillating multi-tool (£45) for one job. Used it once. Waste of money. Should have borrowed or skipped it.
Van #2: Borrowed a friend’s router for edge details. Used it, returned it. Perfect. Didn’t need to own one.
Consider Renting
For single-use or specialist tools:
Hire shops (HSS, Brandon, Jewson) rent tools daily/weekly.
Good candidates for renting:
- Angle grinder: £15-£25/day
- Large compressor: £25-£40/day
- Pressure washer: £20-£30/day
- Scaffold tower: £30-£50/week
When it makes sense:
If you need it for one day and buying it would cost £50+, renting for £20-£30 makes sense.
Where To Actually Buy (UK Specific)
After buying tools and materials for four vans, here’s where I go:
Power Tools
Screwfix: Best prices on Ryobi and DeWalt. Trade card gets 10% off. Good stock.
Toolstation: Similar to Screwfix. Sometimes cheaper, sometimes not. Compare prices.
Makita Power Tools Direct: Online. Often have deals. Where I bought most of my Makita kit.
Machine Mart: Good for specialized tools. Occasional brilliant sales.
Amazon: Price compare. Sometimes great deals. Sometimes more expensive. Read reviews carefully.
Used tools:
- Facebook Marketplace (best for local collection)
- eBay (wider selection but watch postage costs)
- Gumtree (hit and miss)
Timber and Sheet Materials
Wickes: Decent quality ply. Often have 20% off sales. Will cut sheets for free (ask nicely).
B&Q: More expensive but wider range. Good for worktop offcuts.
Selco: Trade-focused. Need trade card but worth getting (free). Cheaper than Wickes/B&Q for bulk.
Travis Perkins: Good quality, trade prices (need account). My go-to for bulk timber.
Local timber merchants: Often cheaper than big chains. Google “timber merchant near me”. Build a relationship and prices drop.
Insulation
Screwfix: Celotex/Kingspan, reasonable prices Wickes: Often on sale Travis Perkins: Good trade prices Insulation Superstore: Online, competitive, delivery included
Fixings and Fasteners
Screwfix: Excellent range, trade card discount Toolstation: Similar to Screwfix Screw Station: Online, brilliant range, good bulk prices Amazon: For specialty fixings
Electrical
12V Planet: Specialist van electrics, brilliant knowledge Amazon: General electrical components Screwfix: Cable and basic components CampervanHQ: Van-specific electrical bits
Plumbing
Screwfix: Everything you need Toolstation: Alternative B&Q: Sinks and taps (good range)
Flooring
Wickes: Good vinyl range B&Q: Wider selection, more expensive Flooring Hut: Online, competitive prices Tile Mountain: Great prices on vinyl
The Three Budget Levels: Complete Toolkit
Let me give you three realistic scenarios for tool purchases.
Budget 1: Minimum Viable Toolkit (£340-£480)
For: First van, tight budget, willing to borrow some tools
Power tools:
- Ryobi drill/driver 18V kit: £65
- Ryobi impact driver (bare): £50
- Bosch jigsaw (corded): £45
- Makita orbital sander (cordless): £75
Hand tools:
- Tape measures (2): £12
- Spirit level: £10
- Combination square: £12
- Screwdriver set: £20
- Socket set: £30
- Adjustable wrenches (2): £18
- Pliers set: £25
- Hex keys: £10
- Clamps (6): £40
Electrical:
- Wire strippers/crimpers: £18
- Multimeter: £15
Safety:
- Safety glasses: £6
- Dust masks (box): £12
- Gloves (3 pairs): £15
- Knee pads: £15
Total: £483
What you’re compromising: Some cheaper tools, no circular saw, borrowing specialized tools
Will this work? Yes. It’s tight but adequate for one build.
Budget 2: Comfortable Toolkit (£700-£950)
For: Serious build, plan to use tools again, want quality that lasts
Power tools:
- Makita drill/driver 18V kit: £125
- Makita impact driver (bare): £95
- Makita jigsaw (cordless bare): £125
- Makita circular saw (cordless bare): £120
- Makita orbital sander (cordless bare): £75
Hand tools:
- Tape measures (2): £15
- Laser measure: £45
- Spirit level: £15
- Combination square: £18
- Screwdriver set (Wera): £35
- Socket set (Halfords): £45
- Adjustable wrenches: £28
- Pliers set (Knipex): £40
- Hex keys: £15
- Clamps (10): £75
Electrical:
- Wire strippers/crimpers (good): £25
- Multimeter (UNI-T): £22
Cutting tools:
- Handsaw: £15
- Hacksaw: £12
- Files set: £18
- Craft knife + blades: £12
Safety:
- Safety glasses (2 pairs): £12
- Dust masks (better): £18
- Gloves (5 pairs): £25
- Knee pads (good): £25
- Work boots: £55
- Ear protection: £15
Total: £1,090
What you’re getting: Quality tools that last, complete set, comfortable to use
Will this work? Brilliantly. This is what I’d buy if starting fresh.
Budget 3: Professional-Grade Toolkit (£1,400-£1,900)
For: Multiple builds, want best quality, long-term investment
Power tools:
- Makita drill/driver 18V kit: £125
- Makita impact driver (bare): £95
- Makita jigsaw (cordless bare): £125
- Makita circular saw (cordless bare): £120
- Makita orbital sander (cordless bare): £75
- Makita angle grinder (cordless bare): £90
- Makita multi-tool (cordless bare): £95
- Extra batteries (2 x 5.0Ah): £120
Hand tools:
- Tape measures (3): £18
- Laser measure (Bosch): £45
- Spirit levels (2 sizes): £30
- Combination square: £18
- Screwdriver set (Wera): £35
- Socket set (Halfords Advanced): £75
- Adjustable wrenches (Bahco): £35
- Pliers set (Knipex): £50
- Hex keys (Wera): £25
- Clamps (15): £110
- Files set: £25
- Chisels set (Bahco): £28
Electrical:
- Wire strippers (automatic): £25
- Ratchet crimpers: £35
- Multimeter (Fluke): £145
Specialist:
- Hole saw set: £45
- Step drills: £25
Safety:
- Safety glasses (3 pairs): £18
- Dust masks (3M 6200 + filters): £37
- Gloves (8 pairs): £40
- Knee pads (Snickers): £25
- Work boots (DeWalt): £55
- Ear protection: £15
- First aid kit: £25
Total: £1,673
What you’re getting: Professional quality, complete set, multiple van builds, comfortable, reliable
Will this work? This is overkill for one van but perfect for serious DIY or multiple builds.
Complete Materials Budget by Van Size
Here’s realistic material costs for different van sizes:
Small Van (SWB – VW Transporter size)
Insulation: £250-£350 Timber/ply: £180-£280 Fixings: £80-£120 Adhesives: £50-£80 Flooring: £90-£140 Paint/finish: £30-£50 Electrical materials: £180-£300 Plumbing materials: £150-£280
Total materials: £1,010-£1,600
Medium Van (MWB – Transit Custom size)
Insulation: £380-£550 Timber/ply: £280-£420 Fixings: £115-£180 Adhesives: £65-£130 Flooring: £140-£235 Paint/finish: £40-£65 Electrical materials: £210-£350 Plumbing materials: £180-£330
Total materials: £1,410-£2,260
Large Van (LWB – Sprinter size)
Insulation: £550-£800 Timber/ply: £420-£650 Fixings: £150-£240 Adhesives: £85-£160 Flooring: £200-£320 Paint/finish: £50-£80 Electrical materials: £240-£400 Plumbing materials: £200-£380
Total materials: £1,895-£3,030
These are realistic materials-only costs. Add your labor (free) and tools (already covered above).
Common Tool/Material Mistakes
Mistake 1: Buying Everything At Once
What I did: Van #1, bought £400 worth of materials before starting. Halfway through, needed different materials. Ended up with unused stuff.
Better approach: Buy materials for each phase as you get there. You’ll adjust plans based on what you learn.
Exception: Buy all insulation at once (prices fluctuate, and you want consistent batches).
Mistake 2: Cheap Blades/Bits
What I did: Bought budget jigsaw blades (£3 for pack of 5). They went blunt after 3 cuts. Needed 20 blades instead of 10.
Cost: £12 for rubbish blades vs. £24 for good blades that last.
Lesson: Blades and drill bits are consumables. Buy decent ones. Bosch, Makita, DeWalt. They last 3-4x longer.
Mistake 3: Wrong Timber Sizes
What I did: Van #2, bought 3×3 timber (70mm x 70mm) thinking bigger = stronger. It was overkill, heavy, and wasted space.
Lesson: 2×2 (47mm x 47mm) is adequate for 95% of van furniture. Only go bigger if you have a specific structural need.
Mistake 4: Not Enough Sandpaper
What I did: Bought one variety pack of sandpaper (£12, 20 sheets). Ran out halfway through sanding. Had to stop work to buy more.
Lesson: Buy two packs. You’ll use it all. Having to stop mid-sanding is frustrating.
Mistake 5: Assuming Materials Match Specs
What I did: Measured a space as 400mm wide. Bought 400mm wide ply. It didn’t fit (van ribs aren’t parallel).
Lesson: Buy oversized and trim to fit. Add 10% to all material measurements. You can cut off. You can’t add on.
Mistake 6: Forgetting About Waste
What I did: Calculated I needed 6 sheets of ply exactly. I needed 7.5 sheets because of wastage from cuts.
Lesson: Add 25% for wastage on sheet materials. 15% on timber. Better to have leftovers than run out.
Mistake 7: Cheap Fixings
What I did: Bought budget screws (£15 for massive box). Half of them stripped or snapped. Drove me mental.
Lesson: Buy decent screws. Spax, Timco, Reisser. They cost 20% more but work properly. Worth it for sanity.
Tool Maintenance (Make Your Investment Last)
Clean tools after use:
- Wipe down power tools (remove dust and debris)
- Clean blades and bits (prevents rust)
- Oil moving parts occasionally
Store properly:
- Keep power tools in cases (protects them)
- Hang hand tools (prevents damage)
- Keep dry (rust is the enemy)
Charge batteries correctly:
- Don’t leave on charger permanently
- Store at 40-60% charge if not using for months
- Run them occasionally (every 2-3 months if stored)
Sharpen/replace consumables:
- Sharpen chisels and plane blades
- Replace dull saw blades (they’re dangerous)
- Replace worn drill bits
Check fixings regularly:
- Tighten loose screws on power tools
- Replace cracked or damaged handles
- Check electrical cables for damage
Tools I’ve had to replace:
- Jigsaw (burnt out the £15 one, replaced with £110 one that’s lasted 6 years)
- Batteries (lithium batteries last 3-5 years typically)
- Measuring tape (lost both original ones, wear and tear on the third)
Tools still going strong from 2018:
- Makita impact driver (thousands of screws, still perfect)
- Socket set (metal doesn’t wear out)
- Spirit level (basic but works)
- Most hand tools (spanners, screwdrivers, pliers)
Final Recommendations: What I’d Buy Today
If I was starting fresh today with zero tools, here’s exactly what I’d buy:
Power tool system: Makita 18V (best balance of cost, quality, range)
Initial purchase (£540):
- DHP485 Drill/driver kit (2 batteries + charger): £125
- DTD154 Impact driver (bare): £95
- DJV182 Jigsaw (bare): £125
- DSS611 Circular saw (bare): £120
- DBO180 Orbital sander (bare): £75
Hand tools (£380):
- Measuring and marking: £80
- Cutting tools: £45
- Spanners and sockets: £90
- Screwdrivers and hex keys: £55
- Clamps: £75
- Electrical tools: £35
Safety gear (£165):
- Complete safety setup as per Budget 2 above
Total toolkit: £1,085
This would handle 95% of van conversion tasks comfortably.
For materials, budget:
- MWB van: £1,800-£2,500 (materials only)
- Tools: £1,085
- Total first-van cost: £2,885-£3,585 (plus the actual van)
Add 20% contingency: £3,462-£4,302
Final Thoughts
Tools and materials are the foundation of your build. You can have perfect plans, brilliant skills, and loads of time, but with wrong tools or rubbish materials, you’ll build rubbish.
I’ve learned this expensively. £480 on tools I didn’t need. £350 on cheap materials that failed. £200 on fixings that stripped or snapped. That’s over £1,000 wasted.
But I’ve also learned where quality matters and where budget is fine:
Don’t cheap out on:
- Power tools you’ll use constantly (drill, impact driver, jigsaw)
- Safety equipment (never)
- Structural timber and ply
- Electrical components
- Cutting blades and drill bits
Budget options are fine for:
- Hand tools that don’t wear out (spanners, hammers)
- Consumables you’ll replace anyway
- Single-use items
- Measuring tools (tape measure doesn’t need to be fancy)
The toolkit I have now – accumulated over many years – has built four vans, two sheds, countless furniture pieces, and done all my home maintenance. Cost per project is actually very reasonable.
If you think about tools as an investment rather than an expense, suddenly spending £1,000 on a good toolkit makes sense. Especially if you’ll use it for years.
Start with the basics. Buy quality where it matters. Add tools as you need them. Maintain what you have.
And for the love of everything, buy decent jigsaw blades. Trust me on this.
Now stop reading and go buy tools. Your van conversion is waiting.
