HiAce Space Cabin
Camper conversion system for the Toyota HiAce
Although I have worked with many clients before in furniture and have developed my own individual product, this was my first freelance project designing a product and helping a customer develop a manufacturing solution for that product.
Type : Interior camper system build
Production Method : CNC Router, cabinetry construction
Scale : 30 units sold (Local manufacturing)
Skills used: Prototyping, CAD Design, Cabinetry
Other Skills: Research, costing
Project Start
The Toyota Hiace is a compact 4wd diesel van that is just making its presence known in the US due to 25 year import laws now allowing early HiAce models on the streets. One of the leaders of this JDM off-road van boom is Danny, the owner at Vanlife Northwest. He imports these early 90’s vans from Japan, then completely revives the nearly 30 year old vehicles and upgrades them to take on all the terrain the West Coast has to offer. The largest problem Danny has run into; he completely restored these vans mechanically, but building out the interior of the van to a fully functional camper was left for the customer to tackle.
One of those super special and specific projects that only the PNW has to offer, I was lucky enough to connect with Danny and was given the task of creating an efficient camper solution for these very unique vans. The first step was to get rough sketches and layouts of the van build. I took the rough measurements of the interior and began blocking in layouts until we found a layout we wanted to move forward with.
Initial design
The blocking continued, but we got more refined through the process and honed in on what we wanted the camper to look like. We used this model to layout how everything would fit in the van checking clearances and other fits. We progressed until we were at a point where we were ready for a prototype.
Creating the prototype
Although the first design was close to being ready for manufacturing, it made more sense for me to make the first prototype using my small workshop and working out the final kinks myself. I took scribes, made sketches and quickly made progress on the first example unit.
Prototype refinement
The rough prototype was finished with a laminate and either edge banding or t-molding to add a vintage camper finish and feel. Things iterated on and improved, different components like the fridge was removed and replaced with a different unit. This model was basically version 1 as I think it did pass the “what is called a prototype” threshold.
Final product
After the first prototype was finished, all changes were updated in CAD. Before it was completed, I located a small CNC manufacturer in Portland to make each future unit. I worked with the owner and helped hand off manufacturing, essentially creating a second business and income stream independent from his import and service work.
Pictured below is the first official space cabin, not produced by me. Grateful to be apart of this project!
