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Tag: Mercedes Vario

A Month of Vario Projects in Germany (And Our September 2026 Expenses)

Vario/T2 Work in Wettenberg

In September, Mark, Maya, and I stayed another ten days at our friends Sandie and Karsten’s property in Wettenberg, Germany, to continue Vario truck maintenance.

(As always, hover over or click on the photos to read their captions.)

Projects included: sanding, taping, and painting behind the removed bumper, greasing the nipples underneath, changing oils and other fluids in the engine, replacing the fuel filters and coolant, installing an RPM gauge in the dash, dealing with air leaks, cleaning the cockpit, replacing air system gaskets, and disposing of old oil, torn-down wood, and metal pieces.

The biggest task was removing the radiator to replace the 33-year-old original belts and the alternator with a bigger one for camper charging reasons. We had to move pulleys for this job and, while the engine was taken apart, I decided to treat existing rust spots with primer and paint.

Breaking out the dinette area was another enormous – and sad – task. Who likes to destroy a perfectly built interior and cause damage while at it? But this had to happen as the existing space was assembled for a single person and wouldn’t work as a seating and sleeping area for two (three).

Mark and I have had numerous layout discussions over the past months. We knew this would be the trickiest part of buying this half-built camper. How do we fit a two-person bed in a defined space that is technically too narrow?

For the longest time, we came up with ideas for an adjustable and adjusted lifting bed. But this system would take up too much space under the ceiling, so we’d lose headspace in the kitchen, or it would have to be an intricate design with a bed that had to be pulled out and converted as well as lowered down.

Because removing existing furniture was to be kept at a minimum to prevent more damage to the inside of the fiberglass box, we seemed to be out of options. We needed to keep the existing upper cabinets. My one rule of not having to make the bed before going to sleep had to be revisited no matter what. In a space that’s only 120cm wide, an always made-up 140cm bed would NOT fit.

Being able to park both campers next to each other saved us the time and hassle of having to move and commute every day. We developed a daily routine of using the bathroom at the nearby cemetery, filling a 10l jug of potable water there, taking Maya for hour-long forest walks, distributing our trash over different garbage bins around town, and cooking dinner at home.

Once a week, we hunted down facilities to empty our cassette toilet, which would be the day to run other errands that were only possible by car. A decent grocery store – and our friends’ house to pick up packages – was only a ten-minute walk away. Our trio was quite happy in Wettenburg. 

A highlight was the visit of our American friends Heather and Jon, who also took advantage of our communal friends’ property to do truck maintenance. The scene reminded me of past boatyard stays – hard days of work with social times in the evening – but this setting was more comfortable than a mosquito-ridden tropical boatyard without facilities.

Of course, while fun, having company made the days longer and the nights shorter, which was exhausting. It was nice to share the space and be in work mode, though. We treated ourselves to one pizza dinner out together and when Sandie and Karsten returned from their camping trip, the six of us had an amazing last dinner and evening together in our “yard.”

After Heather and Jon’s departure, we focused on household tasks, socializing with our hosts, and wrapping up our time on their property. Since the dinette area was now empty, we had to block the water tank, battery, and inverter with tools and parts, so nothing would slide on the ride. It was a live game of Tetris!

Quik Stop in Freudenberg

On our drive back to Much, where our builder Mirko’s workshop and company Premiumcamper is located, we decided to stop in Freudenberg for the weekend. It was nice to take a little break from Vario work, but we kept mulling over our potential dinette/sleeping area for hours and hours. We needed a plan before meeting Mirko on Monday.

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WANTED: 4×4 Mercedes Vario

Readers of this blog probably know that Mark and I have been looking for a very specific van as our new home on wheels. With this vehicle, we hope to explore Europe and beyond – Asia, Africa, and the Middle East when safe again.

A 4×4 Vario in Germany

This next stage of our lives requires a robust, reliable, fixable, durable, and yet comfortable camper. That’s why we are looking for a 4×4 Mercedes Vario, as it ticks all those boxes. The living area and the cab are connected, the engine is almost bulletproof, and these vehicles are known to be resilient. The 4WD part is non-negotiable for us (there are plenty of 2WD versions available) as we plan to venture off the beaten path and know the importance of high clearance and four-wheel drive from our previous overlanding experiences.

But… this particular vehicle is extremely popular and difficult to come by and that’s why I am asking for help. If you know of anyone who might be thinking about selling their Vario or you have one for sale yourself, please get in touch.

Mark and I are interested in just the empty van (to build out ourselves/with a company) or in one that’s already converted into a camper.

You might remember that we have been looking for this type of Vario for a long time. I’d say for almost an entire year. First the research, then pursuing a few options in Chile (which all failed), and then in Europe and elsewhere in the world.

We have followed leads in Peru, Chile, Bahrein, Dubai, Germany (we just returned from a 12-hour drive to check one out that has too many issues and rust), and the Netherlands. It has taken a lot of time, effort, focus, and energy and we are running out of steam… Soon, we will need a different plan and approach.

Thank you for sharing our quest and spreading the word, especially if you are a fellow overlander or someone who knows these kinds of vehicles or owners.

This is how our future camper would look like. This is NOT a 4WD version, though.

Happy May!

Our Crazy Mercedes Vario Idea in Chile – A Waste of Time?

Warning: This is a summarized yet long story about what we have really been doing the last four months.

I’m trying to remember when this crazy idea first emerged. At least six months ago, Mark was researching campers in Europe, since we thought/think this will be our new overlanding location. He must have stumbled upon a Mercedes Vario campervan, thought it looked cool and roomy, remembered our German friends Sabine and Michael having one, and focused his research on the 4×4 kind, only to discover that in Europe you need a special driver’s license for this “more truck than van” vehicle, prices wavered around a steep US$100,000, and there are many rules regarding registration, yearly inspections, insurance, and so on.

Driver’s side view of a Vario

It seemed like the Vario idea dead-ended right there. But on June 3rd (I checked my diary), an available 4×4 Vario appeared on the South America Overlanding Facebook page. There were only two problems: it was for sale in Peru with Peruvian plates and it was not converted yet. We inquired at a shop in Uruguay — the only place in South America we knew about — about how much it would cost to build out a van. More research followed and from the moment we realized that a vehicle can only leave Peru if it is owned by a Peruvian resident and that a new build would cost close to US$90,000, the idea was discarded again.

(As always, click on or hover over photos in galleries to read their captions.)

Fast forward to sometime in August when Mark discovered that Chile had imported hundreds of 4WD Vario vans from Europe to use in the mines as passenger transportation vehicles. Another problem arose: these vans had been well used and came with a bus door instead of a passenger door. Replacing that with an RV door would prove almost impossible, let alone dealing with the paperwork, the language, and other crazy logistics.

Soon after, Mark had a revelation. For months, he’d known about a Vario van that had been built out by a Chilean and had been for sale for a couple of years. It was located along the Chilean coast, four hours south of Santiago, but he hadn’t been interested because the camper section was poorly built and unattractive.

His revelation was this: it had a normal door and two seats in the cab, it was already registered as a camper (as opposed to a company vehicle), and becoming the owner of a new vehicle in Chile was straightforward and popular. It’s why many new overlanders buy a car or camper in Santiago to start their South American overland travels. Why not buy this crappy camper, gut it, and rebuild the living space from scratch?

Passenger side view of the Pichilemu Vario camper – with a normal door

By then, we had found out that there was a company in Santiago — Suzie Santiago CTW — that built out vans for a much better rate — but inferior quality — than the expensive shop in Uruguay. More research and communications followed with companies regarding the build and the paperwork. So many months of work and focus went into this pursuit! It’s pretty much all we did during our five weeks in Paraguay. We even drew up the perfect layout. Fun!

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