When we started our van build, we were convinced we’d never need campsite power. After all, we had solar, a good battery setup, and a love for wild camping. But on second thought, we decided to add it as a back up.
When it’s been raining for three days straight and your solar panels are doing absolutely nothing? That campervan mains electric hook up starts to look like a lifesaver.
This guide is all about installing a 240V hook up inlet – the first step to being able to plug in at campsites
No confusing electrical jargon, no unnecessary extras – just a simple, step-by-step breakdown of what we did (and what we wish we’d known before we started).
Disclaimer: Consult a qualified electrician if you’re not confident in safely installing anything electrical.
What You’ll Need for Your Camper van Hook Up Installation
Before you start cutting holes in your van, here’s what you’ll need:
Essential Parts & Tools:
- 240V hook up inlet socket – The external plug where you’ll connect campsite power (around €30)
- 10mm plywood backing plate – Provides extra support for the socket.
- Hole saw (or jigsaw with a metal-cutting blade) – For cutting into your van.
- Drill & screwdriver – To secure the socket in place.
- Masking tape & pencil – To mark your drill points and prevent chipping.
- Metal file – To smooth out sharp edges after cutting.
- Hammerite paint – To treat for rust
- Waterproof sealant – To prevent leaks around the socket.
- Stainless steel screws – For securing the socket to the van.
Choosing the Best Location for Your Hook Up Inlet
Before you commit to cutting a hole, think about where your campervan 240V hook up is actually going to go.
Things to Consider:
Ease of Access: You don’t want to be crawling under the van to plug in.
Weather Protection: Avoid spots where water could pool or run into the socket.
Cable Routing: The shorter and straighter the internal wiring run, the better.
💡 Tip: If you’re unsure, stick a piece of cardboard where you’re planning to install it and live with it for a day. You’ll quickly figure out if it’s a bad spot!
Step-By-Step Guide: Installing a 240V Hook-Up Inlet
This is the part that feels the most intimidating – drilling a hole in your beloved van. Once you get past that, the rest is just sealing and securing.
Step 1: Creating the Backing Plate for the Hook Up Inlet
Before cutting into the van, we needed something solid for the socket screws to secure into. The metal of the van wall is too thin on its own, so we made a wooden support frame out of 10mm plywood.
How to make the backing plate:
- Place the back of the hook up socket onto the plywood.
- Use a pencil or marker to trace the outline of the hole that needs cutting.
- Using a jigsaw, carefully cut out the hole in the plywood.
- Test-fit the socket to make sure it sits flush.
💡 Why this is important: This backing plate gives the screws something solid to grip onto, so the socket doesn’t wobble or pull loose over time.
Step 2: Marking & Preparing the Hole in the Van
Once the backing plate was sorted, it was time to mark up the van itself.
- Hold the hook up socket in place on the van’s exterior.
- Use a sharpie marker to trace the hole dimensions onto the van wall.
- BEFORE YOU DRILL – Check inside and outside for any obstacles!
💡 Tip: If you’re nervous about drilling in the wrong place, start with a small guide hole first.
Step 3: Cutting the Hole for the Hook Up Inlet
This is the scary bit – cutting the first hole in our pride and joy!!
- Use a 4mm drill bit to create a small pilot hole in the center of your marked area.
- Widen this hole with a step drill bit until it’s big enough for the jigsaw blade.
- Using a sheet metal jigsaw blade, carefully cut out the hole.
- Go slow and steady – let the jigsaw do the work rather than forcing it.
- Once the hole is cut, use a metal file to smooth down any rough edges.
- Treat the exposed metal edges with Hammerite paint (or another rust treatment) to prevent corrosion.
💡Tip: Add masking tape around the cutting area to stop the jigsaw from scratching the paintwork. You can also add duct tape to the base of the jigsaw to protect the paintwork.
Step 4: Installing & Sealing the Hook Up Socket
- Once the paint is dry, apply Sika Primer 210 around the hole to prep the surface.
- Feed the hook up cable through the hole from inside the van.
- Apply a thick bead of Sikaflex 522 around the edge of the socket for a waterproof seal.
- Push the socket into place and align it with the backing plate inside.
- Secure with stainless steel screws these won’t rust over time.
- Add a second bead of sealant around the backing plate inside the van for extra protection.
- Wipe away any excess sealant and let it cure for at least 24 hours before use.
💡 Bonus Tip: Sealing the backing plate as well as the exterior socket adds extra protection against water leaks.
Final Thoughts: Should You Install a Hook Up Inlet?
For us, installing a camper van 240V hook up was worth it. We won’t be relying on it daily, but when we need it, it’ll be a game changer – especially for long stays at campsites.
If you’re still unsure, think about how often you stay at campsites and whether you need mains power. If you’re mostly off-grid, you might not need it, but if you work on the road or use high-wattage appliances, it’s a solid investment.
If you have any questions about DIY camper van electrics, join our Facebook group and ask us/our community! And if you’ve done this install yourself, let us know – what would you do differently?
Continue reading our camper conversion series;
