DHL Sprinter Van Conversion: How We Prepared For Conversion
Embarking on the journey of converting an ex-DHL delivery van into a camper brings its own set of quirks and challenges. From the unmistakable bright yellow exterior to the unexpected surprises hidden within, this transformation isn't easy but worth it in the end. We think an old DHL Van it's a great opportunity to get into Van Life and we love our van now it has been converted into a home. We share the realities of converting an ex-delivery van in the post below.
Contents
Ripping Out Parcel Shelves and the Bulkhead
So, you've decided to take on the challenge of transforming an ex-DHL van into your very own DIY camper. Congratulations! But before you hit the open road, buckle up for a rollercoaster ride of wrenching, drilling, and decoding electronic beeps.
The journey begins with dismantling the DHL van, and let me tell you, it was not easy.
We spent one very long day undoing all the screws, bolts and fastening that held the parcel shelf in place. There were some screws that were so lodged in they are still day today! First we had to remove the shelves which were simple enough then we had to remove the rack which proved challenged and required a range of tools and muscle power. Once the parcel shelves were out we took them to the tip and started a rather large clean up operation.
Due to the van never being cleaned inside the wheel arches were filthy. We cleaned them up and coated them in Rust-Oleum for good measure. We also took up the flooring in pieces (we had to saw the floor apart!) to clean underneath which was a collection of glass, dust and old wrappers of food eaten by deliver drivers.
In the floor where three larger bolts, used for securing larger packages. These were a nightmare to get out they had become rusted and it took several attempts to get them loose. Finally the back of the van was looking clean and tidy ready for the conversion. (We also remembered to Rust-Oleum the plug in the side of the van to prevent any unwanted leaks.)
Finally came the time to take out the bulk head, a heavy metal door that was attached all the way across. The door came off easily and after undoing multiple screws we managed to remove the whole bulk head which was heavy and rattly.
The van was ready for conversion.
Tools and Materials that might come in handy
Hand Tools: Hammer, Screwdrivers etc.
WD-40 for the stuck floor bolts
Tape for marking out your layout on the floor
Lots of cleaning supplies!
Tip: Get wireless tools if you can!
The Dreaded Electrics: Beeping and Battery Problems
When we first received our van we noticed or battery kept going flat. We spoke to the amazing community of DHL Van owners and many mentioned lots of them have a small drain due to wired in electrics. We upgraded to the biggest battery we could fit into our van and we haven't had a problem since. We went with a Bosch AGM. We also got a OEB solar trickle charger to use when we're not using the van as often as we should be.
The other major issue we had was that every time we open the door a high pitch beep is emitted. We learned to live with this but you can turn it off. we have put below some suggestions from other DHL owners who have done just that. For us (and we haven't heard this from any one else) it turned into a bigger problem when our side door wasn't registering as shut. the van entered limp mode and the hazards wouldn't stop flashing. This ended up with an expensive trip to the garage.
Tips We Received From Other Ex-DHL Campervan Owners
Used to have a drain on the battery, a few things… Had an auto electrician in who found a wire going to I think where the DHL PDA on the dash was hard wired in, pulled the fuse on that. Also, had a duff starter motor which I replaced around the same time. Once both of those things were done it massively improved, takes 6 weeks to a couple of months to run down now. I have a solar trickle charger in the window that charges through the OBD port. As for finding the offending device that we pulled the fuse from, basically had the whole dash removed to check for trackers or any third party devices that may have been wired in. On mine, there was a wire behind where the glovebox is that had an inline fuse in it
Also another thing to consider, I got a cheap second hand code reader off of eBay which reads engine codes and tells you about current faults. Reckon it has saved me more than it cost easily!
So we had a battery drain issue when we first got the van, we had a standard NAPA battery. We have AA BRC cover which allowed us to upgrade to a BOSCH AGM battery for only £35 rather than £200+ so well worth having AA if not already! After we changed the battery we’ve had no battery drain issues. I have loads more information if you need help but maybe start with checking what type of battery you have and let me know.
If you want to turn off all the DHL extras for piece of mind it’s not that just remove fuses 17 and 18 for the box under the drivers seat
Here are the steps:
Open Van Driver's Door
Raise seats manually so you can access the fuse box below the drivers seat.
Ensure keys are out of the ignition
With the driver's door open use a screwdriver to click the actual door lock back two clicks into a fully locked position
Open fuse box
Remove fuse 17 and fuse 18
Replace fuse box cover
Pull inner door handle so door lock opens and close drivers door.
Locks should not lock now showing that the slam locks are turned off.
The fuses removed are just powering the additional PSM which DHL and other companies add to allow slam locks and any other setting like speed limiter etc. everything else works as before like alarm etc. any issues give me another shout and I can take pictures if I need to help out. I’ve known people spend £120 + VAT to complete this so nice to get something that works for free!
Our old battery:
The DHL Yellow Aesthetic
The standout feature – the bright yellow colour – adds a touch of eccentricity to your camper project. We love the colour of our camper, it's such a great talking point and its definitely a head turner. When parked up on a campsite we are sunshine in a sea of white. There is also a fantastic community of Ex-DHL conversions out there who are great to connect with.
Built-in Slam Locks
Inherited from its previous life as a delivery van, the built-in slam locks add an extra layer of security. Slam it shut, and your all locked up. The only problem we saw was it was incredibly easy to accidently lock yourself in. Therefore keeping one key outside of the van at all time was a must! Here's the lock box we used.
The inclusion of a reversing camera is a practical addition, and most delivery vans come with one built in which is a bonus! Ours hasn't let us down. The camera is wired into the screen and comes on automatically when the van is put into reverse. You may notice when putting the van in first the picture flashes up but after looking into this is a common problem and doesn't cause any further problems.
Our DHL Van Conversion and Our Home
We love our ex-DHL camper conversion. We love the colour and the quirks, even though at the beginning the conversion was challenging. We decided to run with the yellow theme and create matching window covers.
Throughout our trip round Scotland in Norway many people stopped us intrigued about the van and the colour, some people even asked for pictures!
In the end we unofficially christened her Mustard and we think it fits her perfectly.
Converting an ex-DHL delivery van into a camper is a journey filled with unexpected twists, challenges, and moments of triumph. From battling beeps to conquering rivets, each quirk adds character to your home. Stay tuned for more tales from the road!
Unlock our Sprinter Van Conversion Measurements
Essential Items For a Campervan
 | Omnia Oven Perfect for vans without an oven. You can cook bread, pies, cakes and more just by using your gas stove. This really is a game changer in the kitchen. |
 | Pocket Sized Projector For cosy nights in the van, this is the perfect projector. This projector is small, lightweight but has great picture quality. We love this and use it all the time. |
 | Kärcher Window Vac A must have for condensation which will build up quickly in your van and cause mould. We used this daily in Norway and was a real life-saver in colder weather. |
 | Solar Trickle Charger If you don't drive your van or motorhome enough then this can save the battery from dying. Plug it in and solar energy will top up the battery. |
Tools To Make Your Trip Stress Free
These are some of the travel tools we love and use, by booking through our links you support our blog and help us grow, thank you!
Thank you for reading and enjoy your Van Life adventure. Reach out to us over on Instagram @KateandMikesTravels. We always love to hear from people who read our blogs!
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