05 Vans and Camper Vans
Camper Van Conversions Repair For Lake Forest Owners
Camper van conversions are the fastest growing thing we work on and the type where the gap between shops is widest. A conventional collision shop can repair the van and will decline anything the converter added. A recreational vehicle shop understands the conversion and is not equipped for unibody structural repair or a modern refinish. The vehicles that come to us are usually the ones that have already been declined once, and the estimate starts with an honest assessment of everything that has to come out before any body work can begin.
The construction quality range in this segment is enormous. Professionally converted vans from established builders use engineered mounting, documented electrical, tested sealing and thoughtful weight distribution. Owner builds range from excellent to alarming, and both extremes are common. We do not moralize about it. We document what is there, tell the owner what we found, and repair to a standard that will hold, which sometimes means correcting an original build detail as part of getting a body repair to last.
Weight is an under-appreciated factor in conversion repair. Vans in this segment routinely leave a build shop close to or above their gross rating, and the addition of water, gear, passengers and a roof rack pushes them over. Overloaded vans crack body seams, wear sliding door hardware, sag rear suspension and fatigue roof rack mounting. When we see the same failure twice on the same van, the weight question is the first one we ask, and we would rather have that conversation than repair the same seam a third time.
For Lake Forest owners who use a conversion as a weekend vehicle and a weekday commuter, the practical concern is usually having the van back on a known date with the interior functional. We sequence work so the systems come back up and get tested before delivery rather than after, and we hand the van back with the water pressurized, the electrical live and the fan operating. A van returned with a body repair completed and a house system that will not power up is not a finished job.
What goes wrong on these
Roof penetrations that were sealed rather than flashed
Every conversion adds holes to a roof that left the factory solid: a vent fan, solar mounting feet, a cable gland, sometimes an air conditioner. The common failure is a hole cut and then covered with a bead of sealant on top of the flange, with nothing directing water away from the opening. Sealant on a steel roof in Southern California sun lasts a few years and then cracks at the edge. Water enters and travels between the roof skin and the ceiling panel to somewhere unrelated. Correct repair means removing the fixture, cleaning to bare metal, priming, and re-bedding on a proper sealant system with a mechanical fastening pattern.
Aftermarket window cutouts that removed structure from the body side
Cutting a window into a van body side removes part of a stamped panel that was contributing stiffness through its shape. On a small fixed window this is inconsequential. On a large window, or two windows on the same side, the panel can begin to oil can and the surrounding metal fatigues at the cutout corners. What we see are cracks radiating from the corner radii, especially where the installer cut a sharp corner instead of a generous radius. Repair means stop-drilling and welding the cracks, adding reinforcement around the opening, and refinishing.
House electrical systems that make body repair genuinely hazardous
A modern conversion may carry six hundred amp hours of lithium, an inverter capable of running a full 120 volt circuit, and a large alternator charger, all connected with cable that has no fusing visible from the outside. A body technician grinding near an unlabeled cable run is a real hazard. Our practice is to isolate and lock out the house system, verify absence of voltage at the work area, and document the shutdown before any cutting or welding. We bring it back up in sequence at the end so the owner does not leave with a battery management system in a protective lockout.
Interior structures fastened to sheet metal instead of to body structure
The most common defect in owner built conversions is a bed platform, a galley or a wall panel screwed into the thin sheet metal of a body panel. It holds until the van hits a real bump with a full water tank, and then the fastener tears a hole in the panel from the inside. The visible evidence is a dimple or a small tear on the exterior surface. Repairing the panel without relocating the attachment to a body rib or adding a proper backing plate means the same tear appears three inches over.
Damage we see most
- Roof penetration leaks at fans, solar mounts and antenna glands
- Body panel damage requiring cabinetry removal for access
- Poptop and penthouse canvas tearing and hinge damage
- Window installation leaks at aftermarket cutouts
- Rear door hinge sag from added weight on door mounted storage
- Wall panel separation where adhesive released behind insulation
- Awning rail mounting failure at bonded or riveted attachment points
- Galley and cabinet frame cracking from road vibration
Typical ranges on this vehicle
| Work | Range | Labor |
|---|---|---|
| Van collision repair and refinish | $1,500 to $40,000 and up | 10 to 200 hours |
| Custom van build out | $5,000 to $80,000 and up | 40 to 400 hours |
| 12V electrical, auxiliary battery and inverter system | $750 to $7,500 | 4 to 30 hours |
| Window install | $400 to $3,500 | 2 to 14 hours |
Planning ranges only. The written figure comes from inspecting the vehicle. See all posted rates.
What we do on a camper van conversions
Service
RV Collision Repair
Impact damage repair on motorhomes, trailers and vans, from documented teardown through structural rebuild, panel replacement and refinish.
Service
RV Body Panel Repair
Repair and replacement of exterior panels, compartment doors, skirts, moldings and trim on RVs, trailers and commercial bodies.
Service
Dent and Bumper Repair
Dent work on aluminum skin and fiberglass panels, paintless removal where it is genuinely viable, and bumper or fascia repair weighed against replacement.
Service
Custom Fabrication and Welding
One-off brackets, mounts, racks, reinforcements and replacements for discontinued parts, fabricated to measured dimensions in steel or aluminum.
Service
Roof Repair and Replacement
Membrane, fiberglass and aluminum roof repair, resealing, recoating and full replacement, including decking repair and every rooftop penetration.
Service
Water Intrusion and Leak Repair
Leak source tracing, moisture mapping, controlled water testing, and structural rebuild of framing, decking and panels that water has reached.
Service
Wall and Ceiling Panel Repair
Interior wall board, ceiling panel and headliner replacement, including water stained panels, bowed walls and insulation work behind the surface.
Service
Cabinetry and Countertops
Repair, refacing, refinishing and custom building of RV cabinet boxes, doors, drawers and countertops, plus hardware rated for transit.
Service
Upholstery and Furniture
Recovering and replacement of RV dinettes, sofas, theater seats and cab chairs, with fire rated materials and transit rated anchoring.
Service
Flooring and Subfloor Replacement
New floor coverings plus structural deck repair, including soft spot mapping, rot removal and slide room clearance work.
Service
RV Electrical Repair
Fault isolation and repair across 12-volt and 120-volt circuits, load centers, transfer switches, converters, grounds and branch wiring.
Service
Battery and Charging System Service
Load testing, bank replacement, cabling, disconnect and isolator repair, charger configuration, and lithium conversion with matched charge profiles.
Bring it to the shop from Lake Forest
Collision, paint, fiberglass, roof, slide and systems work, all performed at the Yorba Linda facility. Tell us the vehicle and what happened and we will schedule intake.