Build 001

Every ZomB build starts with the right base. Build 001 begins with a 2023 VW Transporter T6.1 in Pure Grey — a panel van with a clean history and a blank cargo area. The T6.1 is the right choice for this brief. Understated on the road. Solid mechanicals. Enough space to build something serious without tipping into Transit territory. It arrived ply-lined from previous use, at our workshop in rural Derbyshire. The first job was stripping everything back — all fittings, lining and seats out. No shortcuts, no building over someone else's work.

Build 001 base vehicle — 2023 VW Transporter T6.1, Pure Grey

The van arrived with a full ply lining from its previous life. Before anything goes in, everything comes out. Ply panels, floor covering, front seats, all trim. Down to bare steel. It takes longer than people expect. Done properly, it means every decision made from here is intentional — nothing inherited, nothing hidden.

Before and during — ply lining removal

Front seats out, all fittings and lining removed — ready for the build

Before any insulation goes in, the shell needs to be finalised. That means cutting apertures and fitting windows — a precise, irreversible process that has to be right first time. Window placement affects light, ventilation, privacy and the overall look of the finished van. Each position is carefully considered before a blade goes anywhere near the metalwork. At the same time, a swivel base is fitted to the passenger seat — a small detail that transforms how the interior works, turning the front cab into part of the living space when parked.

Side window fitted, passenger swivel base in place

Two of the most significant upgrades to the base vehicle. The pop top roof transforms the interior — standing height when parked, a low profile on the road. The diesel heater is the backbone of the off-grid heating system — reliable, efficient, independent of shore power. Both are fitted before the interior build begins so everything else is designed around them.

Side profile with pop top and full window set fitted

Pop top installation — clean, factory-quality finish

With the shell finalised, first fix electrics go in before insulation covers everything up. Cable runs, solar entry gland and charging points are all mapped and installed at this stage. Getting this right means no chasing cables through finished walls later. Build 001 uses a Bluetti solar generator rather than a conventional fixed lithium install — meaning the entire power system can be removed from the van and used independently. Base camp power, remote working, emergency backup. The van charges it via the roof solar array; unplug and take it with you.

With all penetrations made and first fix complete, the shell is ready to be sealed up. Sound deadening throughout, then full insulation — floor, walls, ceiling. Done properly this is what separates a serious build from a weekend project. The thermal and acoustic performance of a ZomB van is built in at this stage, not bolted on later.

Interior view showing carpet lining, ceiling spots and pop top mechanism (preview of finished feel)

Build 001 is fitted with a quality interior — cabinetry, sleeping platform and living space — designed around the family brief and the off-grid capability spec. The interior components are prepared in the workshop and installed into the van once the shell is fully lined. A considered, functional layout rather than an afterthought.

A simple, honest water system. A compact sink with fresh and grey water tanks housed neatly underneath. Easy to refill, easy to drain, easy to live with. No overengineering.

With furniture in place, second fix electrics connect everything up. Lighting, USB and 12v outlets, 240v sockets, Bluetti integration points and any ancillary systems are all terminated and tested. Finishing details — edge trims, surface finishes, hardware — are fitted at this stage. The difference between a van that's been built and a van that's been finished.

The final phase. Every system is tested, every surface inspected. The customer is walked through the van before it leaves the workshop. Build 001 leaves as a complete, capable, ready-to-go ZomB.