S'more's Outdoors
Project S'mores — the Sienna heading for the mountains at sunset A white Toyota Sienna minivan drawn from the side, driving toward a low sun and layered snow-capped mountains under an orange dusk sky.

Project S'mores · Build Log

Work in progress

A modular, no-drill Toyota Sienna camper conversion

Two people, one 2021–2026 Sienna, the second-row seats out and the third row folded flat. Three lift-out plywood modules clamp into one rigid deck: a compressor fridge and a slide-out camp kitchen pulling straight out the open tailgate, a full-length bed over deep storage, and an EcoFlow battery stack running all of it. Not a single new hole in the vehicle — everything anchors to factory seat rails and cargo hardpoints.

This page grows as the build does. Below: what's finished so far, shop photos, and the complete parts list with what every piece actually cost.

Free download · no signup The full build plan — 127 pages, PDF Everything this page summarises, in full: every dimension, the complete cut list, the bill of materials, wiring and cord routing, the no-drill anchor design, and an illustrated step-by-step manual for all ten modules with exploded views. Drawn from a parametric model, so the numbers in the drawings and the numbers in the text are the same numbers. Download the plan (16 MB PDF) →

Build progress

Updated as work gets done — last updated September 4, 2026.

0 of 0 stages done 0% complete

From the shop

Real photos from the build, added as it goes. Right now that's the leveling legs — twelve of them, and the one job on the whole build that needs a tool most people don't own.

Two drills set up on the bench, one with a depth-of-cut tape flag on the bit, for boring the leg ends
Two drills, so the pilot and the 1‑3/4" bore never swap bits. The tape flag on the bit is the depth stop — the whole leveling stud disappears inside the leg, so the bore depth is the dimension that matters.
Driving a threaded insert into the end grain of a leg with a 10 mm hex wrench, leg clamped in the bench
Driving the 3/8‑16 threaded insert into end grain with a 10 mm (1 cm) hex wrench — the insert's own hex drive. Not 3/8", not 7/16". A long-arm key gives the leverage to start it square.
A leveling foot threaded fully home into the end of a wooden leg, showing the stud, hex collar and pad
The foot threaded home: stud, fixed hex collar, 1‑3/8" pad. Almost no stud showing — which is exactly why the bore has to be 1‑3/4" deep.
The packaging label from the adjustable furniture leveler feet used on the build
The feet, straight off the pack — 3/8‑16 adjustable levelers rated 330 lb each, sold with their own T‑nuts. Kept for the re-order code.
More photos land here as each module gets built — panels, the fridge and kitchen slides, the anchor board, and the first night out.

How it's put together

Front to back, the van reads: front seats → Panel A → Panel B → Panel C → open tailgate. All three panels are open plywood frames on legs, and none of them is fastened to the van. They drop in, then get clamped into a single rigid beam by over-centre draw‑latches at each seam, with alignment dowels for registration and felt strip to kill rattle.

Panel A (front) carries the EcoFlow stack — a DELTA 3 Plus on a locking drawer slide on the right, a WAVE 3 air conditioner in an open bay on the left. Panel B is a bare-frame deep-storage bay: the side doors don't reach it, so it has no drawers and loads from above by lifting out either half of its two-piece top. The full-size spare and its jack kit stow flat down there, at the axle. Panel C (tailgate end) is the working end — a 12 V compressor fridge and a slide-out camp kitchen on heavy-duty locking slides that pull straight out the back, a shallow kitchen drawer in the dead air above them, and a prefab drawer cluster as the rear pantry sitting on its deck.

The panel tops land in one flush plane at 18.5", giving 79¼" of continuous sleeping length for a 78 × 50 × 4" foam mattress. Fridge and cooling fans run off the DELTA 3 on their own DC line, so they keep running with the van locked and the ignition off; the induction cooktop and one power strip plug into the Sienna's rear AC outlet, two short cords away.

Two decisions worth stealing

No drilling, ever. Everything that restrains load ties back to hardpoints the van already has: two steel tongues run forward from a plywood anchor board and pin into the rear ends of the second-row long-slide floor rails, and three ratchet straps drop into the crash-rated third-row striker loops. Nothing is bolted through the floor pan, so the van goes back to being a van in an afternoon.

Leveling lives at the floor, not in the frame. Every one of the twelve legs ends in a 3/8‑16 adjustable foot with ±½" of travel, driven into a threaded insert in the end grain. Tip a corner, turn the foot's hex collar, done — no shimming, and nothing boxes a foot in. Site leveling still happens at the wheels with blocks; that's what the leveling block calculator is for.

Free tools that came out of this build

Most of the calculators on this site exist because a question came up mid-build and there was no good answer online. They're free, need no signup, and run entirely in your browser — they keep working at a campsite with no signal.

The complete parts list

Everything bought for this build, with the price actually paid in July–September 2026 — not a list price, and not an estimate. Prices move; treat these as what a build like this really costs, not as a quote.

Two rows are marked current price. Those tools were picked up mid-build rather than ordered, so instead of a price we paid, their rows link straight to the listing — they're the two tools people ask about most, and worth having before you start.

Legs, feet & leveling 4 items

Twelve feet, one per leg. ±½" of travel around 1" nominal, turned by the stud's own fixed hex collar. Four packs bought.
$13.99 each ×4
The tool this job actually needs. The threaded insert's own drive is 10 mm (1 cm) — not 3/8", not 7/16" — and it's the one tool on the list you're least likely to have out already. This set covers 1.5–10 mm plus the SAE sizes, in chrome-vanadium with a case. Long arm matters: you need the leverage to start an insert square into end grain, and a stubby key will not give it to you.
Site leveling at the wheels — the frame feet only trim the last ½". Pairs with the block calculator.
$28.76
Pitch on the bed platform rail, roll on the rear-pantry deck edge. Two spares in the pack.
$8.99

Frame hardware & fasteners 7 items

Four per panel frame across three panels. Two packs bought, four spares.
$9.49 each ×2
Diagonal racking stiffness for Panels A and B, which have no fixed top of their own to brace them.
$7.99
The piece that turns three loose modules into one beam — two per seam, low on the bottom-rail band.
$14.99
Anti-rattle at every module seam and between stacked drawer units. Cheapest quiet you can buy.
$8.99
Strap anchors screwed inside Panel B's bottom rails, holding the spare-tire stack down.
$12.99 each ×2
The best decision on the build: the custom plywood pantry was replaced by four bought drawer units, stacked two wide and two high on Panel C's deck and held by a cleat pocket and one cam strap. Nothing to build, about 27 lb lighter, and each unit lifts straight out. Match the size, not the brand — 12.1 × 14.3 × 8.4" per unit is what the deck depth was drawn around, so measure before you order.
~$61 2 packs
Bundling every cord run, and tying stacked drawer units to each other so the top row can't creep under braking.
$13.49

Drawer & appliance slides 4 items

The fridge slides. These lock both closed and fully extended — non-negotiable for a 40 lb appliance that pulls out over an open tailgate.
$79.20
The Panel A battery drawer. Only one pair needed — the 5‑pack was cheaper than a single pair.
$46.99
The shallow kitchen drawer hung under Panel C's deck.
$13.48
One per drawer, so nothing opens itself on a corner. A slide's own detent is not enough in a moving vehicle.
$5.99

Anchoring & restraint 5 items

Bolt-on anchor points on the anchor board. Made in USA, and the load rating is printed on them — buy restraint hardware that tells you its numbers.
$39.99
Flush deck anchors for the pantry and battery-drawer straps — nothing to catch a shin on. Three packs across the build.
$29.19 each ×3
Two over the kitchen unit into its own notches, three forward into the third-row striker loops. These are the straps holding the whole platform to the van.
$28.34
Lighter-duty jobs: over the spare stack, across the pantry drawer fronts, around the battery in its drawer.
$14.99
A Sienna doesn't come with a spare. This one stows flat in Panel B right at the axle, where the weight belongs. The single biggest line on the list, and the least negotiable.
$349.95

12 V electrical & fridge cooling 9 items

The one distribution point for every DC circuit. Fuse assortment and labels included.
$17.98
Three needed — fridge, cooktop, fans — on one small control panel. Lit, so you can see what's still on at 2 a.m.
$8.99
Runs the fridge-bay fans on temperature instead of leaving them on all night. A $10 part that pays for itself in battery.
$9.99
One intake, one exhaust through the fridge bay. Ball bearing, not sleeve — a sleeve fan on its side in a hot cabinet has a short life.
$13.99 each ×2
Low intake on the front wall, low exhaust in the cabinet door. Without these the fans are just stirring the same hot air.
$9.97
The fridge's DC run — and the SAE plugs double as the quick-disconnects at each module seam, so the panels still lift out.
$19.94 each ×2
Every wire passing through plywood gets one. Ten pass-throughs on this build.
$9.99
Houses the switch panel and thermostat display so nothing lives loose behind a panel.
$9.89
Spares for the van's own fuse box and the build's. Keep them in the glovebox, not in the shop.
$10.97

AC power & cable management 7 items

Two of them — one on the deck edge, one at the battery. Individual switches mean no phantom draw from whatever's plugged in but idle.
$29.99 each ×2
Deliberately short. The cooktop and power strip sit right beside the Sienna's rear AC outlet — long cords would just coil somewhere and get stepped on.
$8.07 each ×2
Splits the van's single rear outlet between the cooktop and the power strip.
$5.99
The AC channel. Screw it down — adhesive-backed raceway does not survive a hot vehicle.
$28.32
A separate channel for the 12 V runs. Keeping DC and AC in different ducts costs $23 and saves a lot of head-scratching later.
$22.99
Screw-mount, not adhesive. About a dozen used; the rest are cheap insurance.
$8.99 each ×2
For the long bundles nothing else reaches around. UV rating matters if anything ever sees daylight.
$6.99

Kitchen, fridge & galley 7 items

Bought rather than built — a plywood galley with a sink, a folding table and its own slide would have taken weeks and come out heavier. 26 × 20 × 11.8" closed, and it has four of its own strap notches and D‑rings.
$379.00
28 × 17.7 × 15.8", 40.6 lb, 60 W max, reversible lid. Bought direct from the manufacturer — a launch coupon took $27.99 off the $399.99 list, which beat every marketplace price we found. Learn from our mistake: a 30‑quart was ordered on Amazon first and had to go back — measure your fridge bay before you order, not after.
$372.00 $402.69 w/ tax · list $399.99
Induction over propane: no combustion, no CO, no tank, and it drops straight onto the kitchen's stove tray. 18.1 × 9.1 × 4.3". Check your power budget first — 1800 W is most of a 15 A circuit.
$189.99
Handles come off, so the whole set nests into an 11 × 11" footprint. In a van, how something stores matters as much as how it cooks.
$39.99
Sized to the shallow kitchen drawer. Loose cutlery in a moving van is a rattle you will not forgive.
$17.96
Real cutlery. Cheaper over one season than disposables, and it doesn't blow away.
$35.97
Sized for the camp kitchen's counter, not a house sink.
$16.79

EcoFlow power & climate 4 items · $1,876.78 all in

The heart of the build. The DELTA 3 Plus is a 1024 Wh base station running the fridge, the cooling fans and one power strip; the WAVE 3 is a 6100 BTU air conditioner and heater in one box, quiet enough to sleep next to. Buying them as a bundle beat buying the two separately by a wide margin. The power planner is how this got sized.
$1,377.00
Another 1024 Wh, chained to the Plus for 2048 Wh total. Running an air conditioner overnight is what makes the second battery necessary rather than nice — the base station alone will not see you through a hot night.
$409.00
Came free in the same order. Lives in the glovebox for phones — thumb-sized, so it doesn't take a drawer.
$0.00 included
The part that makes a portable air conditioner work in a vehicle at all: a window seal with duct pass-throughs, so the hot exhaust goes outside instead of straight back into the van. Ordered separately, and the piece most people forget.
$39.00 $40.11 w/ tax

Sleeping & shelter 6 items

Doubles the living space off the open tailgate and stands alone on the ground. A pole-frame tailgate tent was tried first and went back — inflatable pitches faster in the dark, by one person.
$299.99
Cut to the 2021–2026 Sienna's glass. Privacy and heat, and far less fuss than making your own Reflectix panels.
$59.99
Personal comfort on the power strip for nights the air conditioner is overkill. Whisper-quiet was the whole reason for it.
$69.00
Clothes storage that hangs instead of taking floor volume. Two bought.
$39.99 each ×2
The dimension the whole platform was designed around — 79¼" of deck length exists to swallow this. Washable waterproof cover included.
~$530 planned
Blackout curtain and tension rod for the cab dividerstill to buy
Separates the cab from the living space. Last item before the first real trip.
~$40 planned

Safety 3 items

Even with induction and no propane on board, you are sleeping in a sealed metal box near an idling engine and other people's generators. $24.
$23.99
Rated for electrical, textile and grease — the three fires a camper van can actually have. Mount it where you can reach it from the bed and from outside.
$11.96
One on each keyring. $6 for the tool you hope never to reach for.
$6.28

Sienna-specific & vehicle 9 items

The part that makes seat removal legal-feeling instead of nerve-wracking. Pulling the second-row seats leaves the airbag and seatbelt-pretensioner circuits open, and the SRS module reads an open circuit as a fault: warning light on, stored codes, and a system you no longer trust. Each emulator presents the 2.2 Ω the module expects, so it sees a healthy circuit. Connector type is the thing to get right — they're sold by connector, not by vehicle. Four units covered our two seats: two round, two square. Check yours against the seller's compatibility table before ordering, and confirm the light stays out and no codes are stored before you drive it.
$80.00 4 × $20
The Sienna's console is a cavern. This makes it usable while driving.
$19.99
The exposed door-track hinges are the first thing to catch grit when you're living out of the side doors.
$49.99
Backing into a dark site is most of van life. The factory reverse bulbs are not up to it.
$20.79
Lights the tailgate work area — where the kitchen and fridge actually get used.
$13.99
Dome, map and door lights converted to LED — brighter, and a fraction of the draw when you're on battery.
$21.75
The festoon fittings the T10 bulbs don't cover. Check which your van has before ordering either.
$14.49
Sand and crumbs are the actual enemy of living in a vehicle. Runs off the battery stack.
$65.99
Unglamorous, and the difference between a tidy van on day four and a bad mood.
$7.99

Tools the build actually needed 9 items

The 48‑89‑9222 kit — a #1 and a #4 jam-free step bit plus eight 1/16–3/16" twist bits. Step bits are what you want for the vent holes, grommet pass-throughs and every sheet-metal or thin-panel hole on a build like this: one bit walks up through a range of sizes and leaves a clean round hole instead of the triangle a twist bit chews in thin stock.
Every curve, every inside corner, and the fillets that keep the one-piece anchor board from tearing. Corded on purpose — no battery to run flat mid-cut.
$54.00
Reverse tooth cuts on the down-stroke, so the good face of the plywood doesn't tear out. Worth it on Baltic birch.
$8.08
The rough-cut pair to the blades above — for breaking a sheet down fast where the edge doesn't show.
$10.72
Panel frames go together square or they don't go together. These hold the corner while you drive the bracket screws.
$28.98
The bit that makes plywood joinery work: ¾" ply is never actually ¾", and an undersized bit cuts a groove the sheet fits snugly.
$13.95
Every edge you'll brush past in the dark gets eased with this. Cheapest comfort upgrade on the build.
$9.95
Pilot, clearance and countersink in one pass. Hundreds of screws go into this build — a split rail costs more than the set.
$31.18
Trimming bolts flush and cutting the L‑track stock down to length.
$19.52

S'more's Outdoors may include Amazon and other affiliate links; if you buy through one, we may earn a commission at no extra cost to you. Prices shown are what we paid in July–September 2026 and are not current quotes. S'more's Outdoors is an independent publisher and is not affiliated with, sponsored by, or endorsed by any manufacturer, vehicle maker, brand, or retailer whose products or trademarks appear on this page; all product names and trademarks are the property of their respective owners.

Before you copy any of this

This is a build log, not engineering guidance. Everything on this page is what worked for one specific vehicle, measured on that vehicle. Two things in particular deserve your own judgement:

Restraint is the safety-critical part. A loaded platform in a minivan is a few hundred pounds behind your head. Anchor points, straps and their working load limits should be verified against your own vehicle's hardpoints and your own load — not copied from a web page. Rated hardware with published numbers is worth the extra money every time.

Removing seats changes your vehicle. Second-row seat removal on a Sienna involves the SRS airbag system, and re-installing seats incorrectly is its own hazard. Know your local regulations on seating positions and belts before you start.

What's coming

New photos and progress go up here as the build moves. Next up are the three panel frames and the no-drill anchor board — the part that decides whether this thing is safe.

Got a question about a decision on this page, or want a tool built for something the build ran into? Get in touch, or use the tool-idea form on the home page — several of the calculators on this site started exactly that way.