Van Conversions: What To Know About Turning a Van Into a Home

Our van is our favorite home ever.

My husband and I bought ours as an empty shell in 2018. It’s since gone through several renovations. Now it’s a full-time, self-contained home on wheels with solar energy, a toilet, an outside shower and an electric refrigerator/freezer. We’ve lived in it comfortably, from sub-zero Colorado nights to balmy afternoons in the sunny, humid Florida Keys.

And yes, I’m sitting in our van right now, writing this article. We’re wild camping on the shores of Lake Powell in Utah. There’s a family of ducks milling about the fire ring, and we hiked a slot canyon yesterday.

But van life is not for everyone. For some, it’s too cramped. Plus, a DIY build can quickly turn into a money pit. Here’s what to consider if you’re thinking about buying a converted van or doing a van conversion yourself.

What is a Van Conversion?

Karuna Eberl For Family Handyman

It’s a cargo or passenger van outfitted into a recreation vehicle with living space. Most include a bed, electricity and storage. Many also feature a counter, sink, shower, toilet and cooktop.

“The main pro of van conversions is that they are customizable and offer a lot of freedom,” says Mitchell Rosko, owner of Paved to Pines. “Plus, you can easily boondock [i.e. camp off-grid without electricity or water hookups], which isn’t true of a lot of larger vehicles.”

Compared with RVs, vans are also easier to drive. They get better fuel economy and are usually more affordable, especially when DIY’d. We take our van down bumpy dirt roads larger motor homes can’t handle. Plus, it fits in a standard parking space at the grocery store.

“On the flip side, van conversions have limited space and may not be suitable for large families or extended travel periods,” says Rosko. “You need to get really crafty with the small space, whether that means dual functional furniture, adding a pop top or a thousand other things to make your van conversion functional.”

How Much Does a Van Conversion Cost?

Karuna Eberl For Family Handyman

It varies, depending on the level of customization and features.

You can buy a factory-converted van from a company like Winnebago or Thor for $150,000 or more. You can also buy one from a custom van builder like Paved to Pines. Those typically run between $35,000 to $125,000 for the conversion alone, depending on the complexity. The van itself is extra.

As for DIY, we spent about $40,000 on ours — $25,000 for the used cargo van itself, then about $15,000 for the conversion. The latter included the building materials (walls, floor, countertop, insulation, etc.), solar system, camping gear (chairs, portable cook top, etc.) and some mechanical repairs. But you could build a bare-bones conversion for just a couple of thousand dollars.

How Hard is a Van Conversion?

Karuna Eberl For Family Handyman

Even for an experienced DIYer, it can be tricky. You need a lot of skills. And of course, you’ll need to know your way around saws, drills and other tools.

Converting a van is far different from remodeling a bedroom or kitchen. For starters, you won’t find straight lines or right angles inside a van. Be ready to build around arcs and support members.

Plus, you must attach your interior walls, wiring and appliances securely to withstand the constant vibrations of a vehicle in motion. A van is a dynamic vehicle that’s twisting, turning and flexing in several directions at once, and this movement will eventually destroy a weak build.

Building a sturdy camper van is critical. Other major systems and considerations include:

• Thermal transfer, insulation and vapor barriers, for controlling temperature and keeping mold and mildew at bay;
• Plumbing, including planning for freezing conditions;
• Electrical wiring, including outlets, lighting, TVs and solar power;
• Ventilation,
• Heating and cooling systems;
• Security;
• Internet connectivity and communications;
• Your lifestyle needs, including hobbies, travel style and comfort requirements;
• Environmental impact.

How Long Do Van Conversions Take?

Karuna Eberl for Family Handyman

The whole process can take weeks to months, not including research and planning. It took us about five months, working on it after work a few days each week. It’s actually still a work in progress, since we’re always finding new ways to make it more efficient and comfortable.

What is the Best Van for Conversion?

The most popular vans for conversions are the Mercedes Sprinter, Ford Transit and Ram Promaster high-top models, per Paved to Pines. They all get decent gas mileage, and parts are readily available.

We went with a Promaster in part because it’s a little wider, meaning it can accommodate my husband Steve’s tall frame on a crossways-installed bed. We chose the Promaster 136 model (as opposed to a longer one) because it fits comfortably and legally in parking spaces, and we wanted to navigate tight switchbacks.

Whatever you choose, thoroughly research potential mechanical issues of specific model you’re considering. Some are prone to costly and frustrating repairs.

What Are the Most Common Pitfalls People Face with Van Conversions?

Steve Alberts for Family Handyman

Getting in over your head. We’ve seen people with a ton of enthusiasm but without the necessary skills or free time. They end up selling a half-completed van for less than they put into it.

Other common problems include:

• Lack of planning, including for layout comfort and ample storage;
• A van that requires excess mechanical maintenance;
• Exceeding the vehicle’s weight limit.

Our best advice: Do your homework, weigh the pros and cons, make a budget, join social media and other help forums, and make certain you have the skills (or know and trust someone with those skills) to complete your project.

“Van conversions can be a rewarding and life-changing experience, but they require a lot of thought and effort to pull off,” says Rosko. “Don’t be afraid to reach out to the van life community for inspiration, support and advice. Remember, every converted van is unique and a reflection of its owner, so make it your own and embrace the journey.”