KNARF BUILD
Knarf Build
The Goal
Knarf is being built to be the ultimate long-distance adventure Vanagon.
Not a show vehicle.
Not a trailer queen.
Not an overland rig built for social media.
A reliable, efficient camper designed to explore North America comfortably for years to come.
Every modification has one purpose:
Reliability. Simplicity. Adventure.
Project Overview
Beginning with a rare 1982 Volkswagen Vanagon Westfalia diesel, the build centers around a mechanical TDI conversion combined with upgraded suspension, brakes, electrical systems, and custom fabrication throughout the vehicle. The goal is to create a camper that's capable of exploring everything from remote forest roads to cross-country highways while remaining easy to maintain.
Engine
The heart of Knarf is a 1.9L AHU mechanical TDI (mTDI) engine featuring a 10 mm injection pump, upgraded .205 injectors, and a Garrett VNT-15 turbocharger. The build also includes custom engine mounts, cooling improvements, and drivetrain upgrades to maximize reliability and efficiency.
Drivetrain
The transmission receives thoughtful upgrades including heavy-duty CV joints, high-angle boots, reinforced mounting bushings, improved shifter components, and other reliability enhancements designed for years of adventure travel.
Suspension & Handling
Comfort and capability are just as important as ground clearance.
Knarf will feature:
- GoWesty lift springs
- Fox shocks
- Reinforced steering components
- Heavy-duty sway bars
- Polyurethane bushings
- Upgraded ball joints
- Wheel bearings throughout
Combined with larger tires, the finished suspension provides over five inches of additional ride height while improving stability both on and off pavement.
Wheels & Tires
The plan calls for 16-inch steel wheels wrapped in Milestar Patagonia all-terrain tires, balancing durability, off-road traction, and highway comfort. Tire size options are being evaluated to achieve the desired ride height without sacrificing drivability.
Brakes
Stopping power receives just as much attention as horsepower.
The build includes:
- BMW brake booster conversion
- Large front disc brake upgrade
- Rear disc brake conversion
- Stainless braided brake lines
- New master cylinder
Designed to inspire confidence whether descending mountain passes or cruising interstate highways.
Camper Systems
Knarf is more than transportation—it's a home on wheels.
Planned upgrades include:
- Refreshed pop-top
- New canvas
- Lift assist
- Custom cabinetry
- Interior lighting
- Plumbing
- Comfortable camping accommodations
Everything is being selected with long-term travel in mind.
Off-Grid Electrical System
One of the most ambitious parts of the build is the electrical system.
Plans include:
- Nearly 1,000 watts of solar
- Victron charging components
- LiFePO₄ battery bank
- DC-to-DC charging
- Bluetooth monitoring
- Future electrical expansion
The goal is to spend extended periods off-grid without relying on campground hookups.
Exterior
Many of the exterior components won't come from a catalog.
They'll be built at Boxer Metal.
Plans include:
- Custom bumpers
- Rear swing-away carriers
- Roof-mounted awning
- Custom exoskeleton
- Recovery equipment
- Adventure lighting
This is where fabrication meets function.
3D Printed Parts
As the project evolves, Knarf will become a test bed for custom-designed 3D-printed components.
From storage solutions to lighting brackets and interior accessories, many future improvements will begin as CAD models before finding a permanent home inside the van.
Some of these designs may eventually be available for download or purchase through Boxer Metal.
Sponsors
Knarf is an ambitious project, and I'm incredibly grateful for the companies and individuals who believe in it.
If you're interested in partnering with the project or having your products tested on real-world adventures, I'd love to hear from you.
Support the Journey
If you've enjoyed following Knarf's story and build, you can help support future adventures by picking up some Knarf merchandise.
➡️ Shop Knarf Merch