On the subject of insurance, I got my insurance from ibuyeco, rang them up and told them about the conversion I planned, no problem. Give them a try, I know some places can be a bit funny with home-made conversions. Also, if you don't min basic a 12v car-battery and an inspection lamp will be more than adequate lighting for your van, and give you a bit of heat too no doubt, I use one in the gazebo. Battery lasts for ever (well, I charge it once a season) with a 40W bulb and much less hassel to install than LB and LEDs.
If looking for ideas try some of the motorcross and sking forums.
WARNING! Possible thread hijack below.
Would be very interested to see some pics from you guys, you seem to know what you are on about.
I'm attempting a smaller scale conversion. I've got a Hyundai Trajet (don't laugh please). Just about big enough for a bed with tools etc underneath and 3 bikes in next to it. Just need a bed, have a gazebo for working on bikes if it's raining and all cooking will done outside on gas.
How should one attach the legs of the bed to the floor? Current thinking is a flat frame of 2x4 on the floor of the boot and then I can easily attach the bed and my home-made bike rack to that. Question really is what is best way to attach the frame to where the seats used to be? Or even directly to the floor? Buying old seat bases from a scrappy and attaching to them costs too much height (Trajet is somewhat smaller than even a Hiace!)
Need to be able easily to remove bed/bike rack and replace seats for use at running races, hence not getting a proper van (and I can't afford a 6 seat T5). On the plus side my interior lighting is already there and I have 4 12v outlets and speakers at the back. Also has a/c in the back for drying laundry whilst travelling. Need to get some nice curtains too. Not sure if rear windoms is advantage or disadvantage over a van. Certainly a plus at funny junctions and when parking!