Custom Convertible Sofa Bed in a Camper Van
Having a custom convertible sofa bed is great for anyone who plans to spend a significant amount of time working, living, or hanging out in their van. The primary benefits to this design include: a more open space, views out all windows, comfortable and spacious seating, and comfortably fitting a queen size bed. Below we will discuss the design features, show 3D models, and provide an itemized list of parts for making the bed (separated into frame, storage, and cushions).
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Components
Building the convertible sofa bed involved four stages: frame, storage, cushions, and electrical. The electrical refers to our battery storage and electrical system, which are located under the left side of the couch. This will be discussed in a later article.
Note: Below this point, the frame will be depicted using three shades (silver, grey, and black) to help differentiate between each section.
Design Features for a Convertible Sofa Bed
Many people add a platform bed in the back of their van to maximize storage space. However, because we work out of our van and knew we would be spending a lot of time inside it, we wanted to make the space was comfortable. So, we came up with a different sofa bed design.
The design features we wanted to incorporate include:
- Open space — bed converts into a sofa
- Views out all windows — sofa is located behind driver’s seat
- Comfortable and spacious seating that reclines — quality foam cushion material and segmented into three parts
The cushions can be reclined by pulling a 1/3 of the frame out further and the sofa can be converted into a bed.
- Comfortable cushions for sleeping on — two different densities of foam for the right amount of firmness
- Cushions that don’t separate throughout the night — cushion covers that zip together
- Bed that is quick and easy to setup and put away — cushions can be folded such that they never need to be unzipped (except for transporting)
- Bed that can be setup without opening any doors — width of bed is slightly smaller than the width of the van
- Floor doesn’t need to be cleared to setup bed — frame segmented into three parts with support legs not being joined
- Queen size bed — almost, -5″ in length
Left – Cabinet support for anchoring the fridge. | Right – Vertical, movable post.
- Leg supports that won’t wear the floor overtime — used ultra high molecular weight polyethylene (UHMW) as feet for the legs
- Easy to clean cushion covers — easily removable with zippers and being divided into three segments
- Storage underneath — compact frame allowing room for a built in drawer and long-term storage space
- Access to all storage areas — hinges in frame allowing for the top of the frame to be easily lifted
Frame
The frame consists of three movable parts, as well as, a stationary base (silver) that is anchored to the floor and wall. The top of the frame rotates on two hings, allowing access to the storage space underneath. The black section of the frame is bound between the bed slats and grey section of the frame (hard to see in the figure below) and moves in and out, forming the second 1/3 of the bed. The 3/4″ Euro Poplar sheet rotates on a piano hinge forming the third 1/3 of the bed. It rests on the section of cabinet anchoring the fridge to the van and a vertical leg.
Click on the points to learn more about each part. | * The 1″ Ultra High Molecular Weight Polyethylene is depicted incorrectly (as metal feet) in this model.
Extruded Aluminum
Most of the bed frame was built using extruded aluminum from 80/20 Inc. Not only is extruded aluminum easy to work with, but it is lightweight, very strong and easy to anchor to the van’s frame. 80/20 Inc. sells extruded aluminum at a reasonable price and provides an option to machine all of the parts for you, which will save you time.
Product Name | Source | Part # | Specs | Machining | Qty | Cost |
---|---|---|---|---|---|---|
3.16″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 1 | $2.68 |
16.5″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore x2 | 3 | $30.75 |
17.313″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore x2, End Tap | 3 | $37.14 |
17.5″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 1 | $5.98 |
17.5″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore | 1 | $8.23 |
18.5″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore | 1 | $8.46 |
21″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 3 | $20.34 |
21″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore | 1 | $9.03 |
21″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore x4 | 3 | $47.34 |
21″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | End Tap | 1 | $8.73 |
22″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 2 | $14.02 |
23″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 2 | $14.48 |
38″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 1 | $10.69 |
68.68″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 1 | $17.75 |
68.68″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore x4 | 1 | $26.75 |
71″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore x4 | 1 | $27.28 |
73″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | Counterbore x4 | 1 | $27.74 |
75″ Extruded Al (4 Open T-Slots) | 80/20 Inc. | 1010 | 1.00”x1.00” T-Slotted Profile | – | 2 | $38.40 |
68.68″ Extruded Al (6 Open T-Slots) | 80/20 Inc. | 1020 | 1.00”x2.00” T-Slotted Profile | Counterbore x2, End Tap | 1 | $37.04 |
Total | $392.83 |
Joinery, Wood, Support Pieces, Etc.
The bed slats and bed platform were built from 3/4″ Euro Poplar to save weight. Ultra High Molecular Weight Polyethylene was used as feet for the support legs to keep from damaging the floor.
Product Name | Source | Part # | Specs | Qty | Cost |
---|---|---|---|---|---|
Short Double Anchor Assembly | 80/20 Inc. | 3090 | 10 Series 10-32, Zinc | 15 | $78.75 |
Push-In Fastener | 80/20 Inc. | 3272 | 10 Series, Plastic | 3 | $0.39 |
Bolt Assembly (w/ FBHSCS) | 80/20 Inc. | 3321 | 1/4-20x.5″, T-Nut, Steel, Zinc Plated | 21 | $10.50 |
Standard Anchor Fastener Assembly | 80/20 Inc. | 3363 | 10 Series 10-32, Zinc | 11 | $44.00 |
Bolt Assembly (w/ BHSCS) | 80/20 Inc. | 3393 | 1/4-20×0.5″, T-Nut, Steel, Zinc Plated | 44 | $17.60 |
Bolt Assembly (w/ BHSCS) | 80/20 Inc. | 3479 | 1/4-20×0.75″, T-Nut, Steel, Zinc Plated | 2 | $1.06 |
Roll-In T-Nut w/ Ball Spring | 80/20 Inc. | 3668 | M6, Stainless-Steel | 8 | $20.40 |
Slide-In Economy T-Nut | 80/20 Inc. | 3675 | 1/4-20, Centered-Thread, Stainless Steel | 50 | $30.50 |
BHSCS | 80/20 Inc. | 3688 | 1/4-20×0.375″, Stainless-Steel | 8 | $2.32 |
Straight Flat Plate | 80/20 Inc. | 4118 | 10 Series 3 Hole, Anodize | 1 | $4.30 |
Gusseted Inside Corner Bracket | 80/20 Inc. | 4132 | 10 Series 2 Hole, Anodize | 14 | $55.30 |
Wide Gusseted Inside Corner Bracket | 80/20 Inc. | 4134 | 10 Series 4 Hole, Anodize | 5 | $28.25 |
90º Angled Squared Flat Plate | 80/20 Inc. | 4152 | 10 Series 7 Hole, Anodize | 4 | $30.60 |
21″ Standard Sliding Door Glide Profile | 80/20 Inc. | 6710 | 10 Series, Standard, UHMW | 3 | $45.54 |
2″ Angle Profile | 80/20 Inc. | 8212 | 1″x0.188″, Anodize | 2 | $5.42 |
Standard Stainless Steel Hinge | 80/20 Inc. | 12094 | 10 & 25 Series 4 Hole, Stainless Steel | 2 | $37.80 |
FHSCS | 80/20 Inc. | 17-6712 | M6x12mm, Stainless-Steel | 8 | #3.20 |
End Cap w/ Push-In Fastener | 80/20 Inc. | 2015-plain | 10 Series, ABS | 7 | $8.40 |
Hex Drive Flat Head Screw | McMaster-Carr |
92210A542
|
1/4-20×1″, Stainless Steel | 50 | $8.84 |
Spring-Loaded Ball Fastener | McMaster-Carr | 47065T226 | 1/4″-20×1″, Zinc-Plated Steel | 24 | $38.20 |
Aluminum Sheet | McMaster-Carr | 8975K599 | 1/4″x2-1/4″, Aluminum | 2 | $21.59 |
Tight Clearance Piano Hinge | McMaster-Carr | 11555A68 | 6’x3″x0.075″, Stainless Steel | 1 | $59.54 |
Phillips Flat Head Screws | McMaster-Carr | 90294A244 | #10×5/8″, Stainless Steel | 50 | $7.77 |
3/4″ Euro Poplar | Rugby Architectural Building Products |
– | 4’x8′ | 0.65 | $39.64 |
Wood Paste Wax | Home Depot | 203 | SC Johnson Fine Wood Paste Wax, 1lb | 1 | 6.47 |
1″ Ultra High Molecular Weight Polyethylene | Amazon | – | 12″x12″ | 0.021 | $1.13 |
Total | $624.12 |
Storage
Product Name | Source | Part # | Specs | Qty | Cost |
---|---|---|---|---|---|
20″ Steel Drawer Slides | McMaster-Carr | 11435A26 | Steel, 100lb load capacity | 1 | $21.63 |
Southco plastic pop-out knob | Amazon | M1-2A-13-5 | Black | 1 | $12.63 |
1/4″ Euro Poplar | Rugby Architectural Building Products | – | – | 0.074 | $2.67 |
1/2″ Euro Poplar | Rugby Architectural Building Products | – | – | 0.748 | $32.61 |
1/2″ Red Oak | Rugby Architectural Building Products | – | – | 0.258 | $15.14 |
Total | $84.61 |
Cushions
We chose to use three cushions, instead of one, so that they could be both a bed mattress and cushion with a back for the sofa. To join the cushions, three cushion covers were sewn and joined by zippers.
Product Name | Source | Part # | Specs | Qty | Cost |
---|---|---|---|---|---|
24″ Firm Foam | Foam N’ More Inc. | – | 75″x3″, Luxury-Firm High Density Custom Order | 1 | $54.71 |
18-13/16″ Firm Foam | Foam N’ More Inc. | – | 75″x3″, Luxury-Firm High Density Custom Order | 1 | $44.94 |
17-3/16″ Firm Foam | Foam N’ More Inc. | – | 75″x3″, Luxury-Firm High Density Custom Order | 1 | $42.99 |
24″ Premium Foam | Foam N’ More Inc. | – | 75″x1″, Luxury-Premium Medium High Density | 1 | $22.21 |
18-13/16″ Premium Foam | Foam N’ More Inc. | – | 75″x1″, Luxury-Premium Medium High Density | 1 | $19.21 |
17-3/16″ Premium Foam | Foam N’ More Inc. | – | 75″x1″, Luxury-Premium Medium High Density | 1 | $18.61 |
Grosgrain Polyester Binding | Sailrite | 105421 | Black, 1″ | 300 | $55.51 |
Thread Nylon V-69 | Sailrite | 106137 | UV Bonded Black 4oz | 2 | $33.41 |
Sunbrella Canvas Regatta Fabric | Sailrite | 5493-0000 | 54″ Upholstery Fabric | 14 | $300.10 |
#10 One Way Separating Marine Zipper | Seattle Fabrics | – | 72″, Black | 2 | $17.00 |
Vislon Metal Sliders | Seattle Fabrics | – | #5, Black, Single | 3 | $1.50 |
Vislon Zipper Tape | Seattle Fabrics | – | #5, Black | 6 | $12.00 |
Queen Size Mattress Cover | Amazon | B007BFKNUE | Hypoallergenic, Waterproof, Vinyl Free | 1 | $21.95 |
Total | $644.16 |
I’M INTERESTED IN THE BED FRAME ONLY, HOW MANY INCHES LONG ? FOR HOW TALL A PERSON? CAN SOMEONE BUILD AND INSTALL FOR ME OR DOES THE FRAME COME WITH DETAILED INSTRUCTIONS?
Hi Julie, upright/seated, the dimensions are roughly:
44” – height from floor to top of back cushion
25” – height from floor to top of cushion you would sit on
21” – height from floor to top of couch-bed frame/bottom of cushion you would sit on
24.16” – depth of frame, from back wall to front of cushions.
75” – length of frame
Unfortunately, we do not build and install these frames for people. However, we can send you the model and you can reverse engineer it. If interested in this option, please send us an email for more details.
Hi
Wow can I say this is a brill idea, is there anyway to get detailed measurements of this bed? I’m gonna try make it out of furniture steel for my campervan project .
Thanks a mill
Ken
Thanks, Ken! Upright/seated, the dimensions are roughly:
44” – height from floor to top of back cushion
25” – height from floor to top of cushion you would sit on
21” – height from floor to top of couch-bed frame/bottom of cushion you would sit on
24.16” – depth of frame, from back wall to front of cushions.
75” – length of frame
Hope this helps and let us know if you have any more questions!
Hi guys, brilliant design! Not sure if I’m commenting in the right place but had a Q about how in couch mode that the couch back locks at an angle? Good eat stuff!
Hi Jesse, the couch doesn’t “lock” at an angle, but there is enough friction between the couch and bed frame such that the couch remains at an angle when configured this way.
Hello! I found your post very intuitive for someone building my own similar couchbed. My next step is making my cushions, is there anything you would have done differently with the interior foam combination to make it even more comfortable now that you’ve lived with it for quite a while?
Thanks! Ben from Montana
Hi Ben, we are still super happy with our cushions. Here’s an article for additional details on how to make them yourself: https://meanderingexplorers.com/diy-bed-sewing-van-cushions/
thank you for the details. I have Toyota Hiace with a folded out (in 3 joined sections) type of bed which doesn’t suit me. I think I can adopt your idea to fit my constraints which is exciting. Thanks again.
Perfect, thanks Kay!
Wow! Great job! What are the dimensions when it’s in the upright/seated position?
Thanks Suzanne! Upright/seated, the dimensions are roughly:
44” – height from floor to top of back cushion
25” – height from floor to top of cushion you would sit on
21” – height from floor to top of couch-bed frame/bottom of cushion you would sit on
24.16” – depth of frame, from back wall to front of cushions.
75” – length of frame
Hope this helps and let us know if you have any more questions!
Looks great! I’ve been importing the KEI Japanese mini vans/trucks for a little over eight years now. I’d like to reference your great looking beds on our website! Keep it up and have fun! Tony Childs/Mayberry Mini Trucks
Fantastic explanation on how you created your sofa/bed. Really enjoyed reading this. We are doing something similar and this has helped focus our plan
Thanks, Gavin!
This looks like what I need! You mentioned and electrical section. What role does electricity play in this bed?
Hi Anne, good question. The we store all of our batteries and electrical setup under the left side of the couch. The 80/20 is perfect for safely anchoring these components to the van and help make the system more modular, if we decide to change some of the electrical design later on.
How do I download this to Excel?
Hi Travis. Unfortunately, this information is not available for download to Excel. Please let us know if you have any other questions!
A storage ottoman could be an alternative to the supports for the final third.
Can you leave bed linens on ? I would need to convert sofa to bed and back every day. Maybe a custom slipcover for the sofa configuration would allow bed linens to stay on the trifold cushions.
A storage ottoman sounds like a great idea!
I wouldn’t suggest leaving the bed linens on, as the cushions fold in a way that the underside (bed configuration) becomes the top side (couch mode). But, yes, you could probably design a custom slipcover. That said, we just put the sheets on each night. And, the cushion cover fabric hides dirt pretty well, so we don’t worry about covering them when we sit. But, we also try to avoid spills and occasionally (once/year) wash the cushion covers.
This is a brilliant idea. Do you know how much weight the bench/bed hold? We are just starting our conversion and I can see the Ideas now. Thank Cindy
Thanks, Cindy! No we do not know how much weight the bench/bed hold. But, we have had five people sitting on the couch at once (strongest configuration). For the bed configuration, the piece that folds out by the sliding door would definitely be the weakest component. We’ve never had a concern about the strength of the bed, and we’ve had three people (~135-180 lbs each) on it.