10 Regrets and Mistakes from My Off-Grid, DIY Minivan Camper Build

Today, I’m going to share 10 regrets I have from my minivan camper build. Not all of them were outright mistakes, but a lot of these issues have been frustrating, costly, and time-consuming. If you’re thinking about converting a minivan into a camper, learn from my experience and avoid these pitfalls!

Links to products, devices and gear featured in this video

Regret #1: My Minivan is Too Small

I bought a 2006 Mazda MPV minivan because it was affordable, had low miles, and was in great condition. The problem? I didn’t check the interior dimensions before buying it. At over six feet tall, I quickly realized that this Mazda is much smaller than Toyota, Honda, and Dodge minivans. I really wanted a Toyota Sienna AWD, and if I could do it over again, I would have waited for the right van instead of settling for what was available at the time. The smaller size has forced me to get extremely creative with my layout, building a folding sofa bed, modular furniture, and a hidden toilet to make it work. But honestly? A bigger van would have solved so many of these headaches from the start.

Regret #2: The Sofa Bed Was Too Wide

My first folding sofa bed was built before I even bought the van. I used a twin XL folding foam mattress (38 inches wide) and paid a professional to upholster the cushions. But once I installed it, I realized it took up way too much space. I had to cut the entire frame down to 30 inches and pay again to reupholster the cushions. Lesson learned: don’t build furniture before you know the exact dimensions of your space.

Regret #3: The Sink Box Was Too Wide

My first sink setup was too wide and heavy, with thick wood, a deep stainless steel sink, and a slide-out shelf for a coffee pot I never even used. The biggest issue? It blocked my ability to drop the sofa bed into sleep mode unless I moved the driver’s seat forward and slid the sink box forward. That meant I couldn’t stealth camp because I had to get out of the van just to set up my bed. I eventually built a narrower, more practical kitchen box that stays in place, but I wasted a lot of time and money getting there.

Regret #4: The Hidden Toilet Dilemma

A hidden toilet sounded great in theory, but the execution didn’t work so well. I built a custom low-profile composting toilet with a 3D-printed urine diverter and an exhaust fan, but the box doubles as a support for my folding countertop. That means I can’t use the toilet when the counter is folded down—which is most of the time! Now, I primarily use a folding toilet in an outdoor privacy tent.

Regret #5: Overcomplicated Shower Tent Setup

My first shower setup involved a DIY curtain hanging from tent poles threaded into tiny eye bolts on my roof rack. It looked cool but took 15 minutes to set up and collapsed in the wind. I eventually upgraded to a commercial shower tent that sets up in under a minute. Sometimes, simpler is better.

Regret #6: My Complicated Roof Setup

I started with a plan to have a small awning and a single solar panel, but I kept adding gear. Now, my minivan has three gearboxes, a Thule roof box, three solar panels, and a massive awning, making it over 7 feet tall. To access my roof storage, I have to lift the solar panels, prop them open, and climb onto a bucket or step ladder—annoying on short trips. A redesign is definitely needed.

Regret #7: Placing My Power Station in the Trunk

I originally placed my power station in the deep storage space where the third-row seats used to be. Seemed like a perfect fit—until I realized I had to physically turn it on and off. That meant going outside, opening the hatch, moving cushions, and lifting a panel. When I later added a swing-out cargo carrier, it made access even harder. I eventually upgraded to a power station with an app, allowing me to control it remotely, but the initial setup was a major hassle.

Regret #8: No Cooler Ventilation

I installed two portable 12V coolers next to each other without testing them for long-term use. Big mistake. They overheated, drained my power, and barely kept my food cold. I ended up throwing out all my food on a road trip. The fix? Cutting ventilation holes and downsizing to one larger cooler in the front. But now, that fridge blocks access to my lower storage. It’s a trade-off I still struggle with.

Regret #9: Poor Shelf Storage in Transit Mode

I built a versatile removable shelf that doubles as a workbench and a food prep table. It’s one of my favorite features, but I have no good way to store it while driving. In transit mode, it blocks my access to food storage and my microwave, and I can’t convert my sofa into a bed without removing it. Not ideal for road trips when I need quick access.

Regret #10: The Thule Roof Box Nightmare

I have a love-hate relationship with my Thule roof box. The problem? The locking mechanism frequently jams when gear shifts inside. Sometimes, I can’t get the key out, which means I risk the box popping open while driving. The only way to fix it is to climb up and physically beat it until it unlocks. It’s beyond frustrating, and I wouldn’t buy another one unless they improve the design.

Final Thoughts

This camper van build has been a wild ride. I love the creative solutions I’ve come up with, but many of them were solutions to problems I created myself! If I had kept things simpler from the start, I would have saved time, money, and frustration. If you’re planning your own camper build, my advice is: don’t overcomplicate it. Keep it simple, test everything, and plan for ease of use.

Until next time, thanks for reading—I’ve got to get back to banging out my frustrations! (see the video to see what I mean)