In May of 2017, I bought a used Ford Transit Cargo Van and began converting it into an off-grid mobile home named Casper. The process took about 2 months while working on it part-time and cost about $3,480.
About the Van
Casper is a 2016 Ford Transit-250 Cargo Van, which I bought for $24,000 with a little over 18,000 miles on it. Casper gets on average 18.5 mpg and takes both ethanol and regular fuel.
Before purchasing the van, I examined and test drove a Mercedes Sprinter, Chevrolet Express, Dodge Ram ProMaster, and a few other passenger and cargo vans. Many of the other vans I looked at were much cheaper, but had low fuel-efficiency, already had a lot of miles on them, and were no longer under warranty. As a solo female traveler planning to camp off-grid in rural settings, safety was a high priority for me. Meaning, I didn’t want something that will be breaking down in the middle of nowhere. I’m also concerned about my carbon footprint, so I wanted something with decent gas mileage and flexible fuel options.
In the end, I chose my van because it is flex-fuel, “stealthy”, aerodynamic, drives smoothly, and is still under warranty. I bought the van on credit, for those who wonder how I could afford $24,000.
I love my van, but if I could do it again, I would buy a van with a high-top, so I could stand up inside and have more room for cabinetry and storage. I’ve already looked into installing a high-roof extension, and the cheapest quote is $5,000. So stay tuned, to see if I decide to splurge on comfort 🙂
The Conversion Process
The conversion was a somewhat sporadic endeavor, spanning 2-months, while working off and on with the help of friends and family. I didn’t keep thorough track of how many hours I spent working on the van build, but I’d guess about 100 hours of labor went into it.
I included a cost sheet of all the building expenses at the bottom of this post with names of specific materials. I also added screenshots of products I used in my conversion that I highly recommend in your own van build. I purchased almost everything for the van on Amazon or at Home Depot.
I used quite a few resources to get started, mostly Youtube van conversion tutorials, Pinterest for design and layout ideas, and The Vanual.
DISCLAIMER: Even with all the preparation, the build consisted of a lot of trial and error- considering I had ZERO woodworking experience prior to the van. This is an amateur van build, so feel free to take my suggestions and lessons with a grain of salt. In most cases, I chose the easiest, quickest, cheapest options (with the exception of the solar battery system) because I was anxious to get on the road. I don’t claim that this is the best way to convert a van, but everything we built has been working well for over 5 months so far.
So without further ado, here’s how it all went down…
Casper, came quite bare, with these wood beams on the side, which I decided to leave on. It also came with a metal partitioner in the front, behind the driver and passenger seats, which I had taken out at the car dealership I bought the van from.
Step 1. Making the Floor & Insulating the Van
I started by cleaning and insulating the floor.
I did this by cutting and taping together pieces of reflectix (with reflectix foil tape), until the floor of the van was covered. After I had the floor insulation mapped out, I used my reflectix blueprint to trace the shape of the floor around the wheelbases onto plywood, which I then pieced together like puzzle pieces to create a floorboard.
Then I gathered my mom’s tools and borrowed two saw horses from my neighbor, and we got to work.
We measured (twice), chopped, and screwed the floorboards directly into the van, over the reflectix insulation.
We used two pieces of 8′ x 4′ plywood to create 4 separate puzzle pieces around the wheelbase and side stairs.
Then we glued in some “wood” sheet vinyl for the finishing touch. We used Sheet Vinyl Adhesive, which is durable but dries quickly. So we did it in sections and placed bricks on top of the vinyl to help secure the vinyl to the plywood and assist the glue to set in.
After the floor was done, we insulated the walls with a layer of reflectix, and then on top of that, we added pure safety insulation rated at R15 (the white wool looking strips). Luckily the wood beams were already in place along the walls and made this process much simpler by holding the insulation in place.
Step 2: Building the Bedframe and Storage Spaces
We built a bed frame and storage units with scrap wood and with leftover plywood from the floor. We deliberately designed the layout of the van around a chuck box that my mom built with her dad. We incorporated the chuck box so that it would act as part of the support system for the bed and could be used as extra storage and a countertop for cooking on a portable stove when the chuck box is open.
I wanted to be able to access my storage spaces from multiple areas. So I left openings in the front and back of my bed frame, and a small side hole. For the driver side storage unit, we created two separate hinge doors, for top loading storage access.
I also created the layout so that I could have a small bed with a table and couch, or I could convert it to a larger bed when I’m not using the table.
The chuck box is not a permanent fixture in the van (which was a part of the design), so after we created the bedframe and side storage unit, we took the chuck box out to make it easier to move around during construction.
I screwed in some plywood to make the top of the bedframe (on the right), and created hinge lids out of plywood for the storage spaces (on the left).
We also built, a cubby hole for my bathroom. That green bucket with the white lid is my toilet (in the picture below).
Step 3: Installing the Walls
I used foe wood wall paneling for the walls, which was simple enough to screw directly into the horizontal wood beams on the side of the van. I used this because it was quick and easy but still looked good. It’s worked fine so far, but I do plan to replace the wall paneling with real wood soon.
Step 4: Building the Kitchen
My neighbor John let us use his workshop and helped give us guidance on how to tackle the kitchen. At this point, I had already bought a refrigerator, so we built the kitchen countertop and shelves around those dimensions. Utilizing his drafting knowledge and his table saw really helped speed up the process.
I went through a few stainless steel bowls, attempting to drill holes in them to make my own sink, before giving up and buying a $20 Sterling Oval Single Basin Self-Rimming Undermount Sink from Amazon Warehouse.
Once I had the sink I was able to saw out the hole in my kitchen countertop.
I then used the extra wood to build a table. I screwed in a table base that I bought on Amazon to the table, and another on the floor of my van.
I also created a plank that would complete my bed when I wasn’t using the table.
After I had all my pieces sawed out to the appropriate measurements to fit in the van, I sanded them, stained them, and left them out to dry.
Then I used silicone to seal my sink into the counter and drilled in my new hand pump faucet.
I installed my kitchen, with my side loading AC/DC fridge, my new 3-in-1 breakfast center, and my new table.
Step 5: Plumbing
I used two 5 gallon water containers for my plumbing system (one for input and one for output/gray water). I ended up storing my water output jug under the bench seat, and kept the input water jug directly under the sink.
I used braided vinyl tubing to connect my faucet and drain to the water containers and metal clamps, flex coupling and PVC bushing to secure them in place.
Step 6: Making the Bed
I bought a queen size 6-inch memory foam mattress for my van bed. Which I highly recommend since I’ve been sleeping on it for months and getting some of the best sleep of my life.
I traced out the pieces with chalk, directly on the mattress, and then cut the mattress with a bread knife into 5 separate pieces that make a couch and a bed, or they can combine to make one large bed.
I picked out the fabric at Walmart and my aunt upholstered all my cushions for me.
Step 7: Installing the Roof
We saved the roof for last, because we had no idea how to tackle it.
We spray glued the insulation (reflectix and pure safety) to each other and then glued and taped it to the roof with reflectix foil tape.
Then we screwed in the same foe wood paneling we used for the walls. We ended up trimming the paneling around the fantastic fan with a jigsaw, and later cut out a hole for the FantasticFan air vent.
Step 8: Fantastic Fan and Solar Panel Installation
We hired people to install our vent and solar panels, because we didn’t feel comfortable cutting or drilling holes into the roof of the van ourselves.
I bought a FantasticFan on Amazon and took it to RV Renovators in Mesa, AZ to install. They did a fantastic job 🙂
We bought two 160 Watt 12 Volt solar panels, and my mom’s friend installed them on the roof of the van for us.
We then connected them to a Goal Zero Yeti 1400 Lithium power station inside the van.
Step 9: Curtains and Black Out Shades
For the final touches, my aunt hemmed some black out curtains for behind the driver and passenger seats and used the excess fabric to sew curtains for my kitchen area.
I hung all my curtains with tension rods, which I also used on my shelves to secure things while I’m driving.
Finally, I used excess Reflectix insulation to cut out window shades. I then spray painted them black so they don’t stand out as much from the outside of the van.
In the end, I spent $3,480 on my camper van build.
$1800 of that, was for the Goal Zero Power Station. So $1,680 was for materials, appliances and construction. The conversion could have been much cheaper, had I gone a different route on my solar electric system. But I didn’t have the skills to wire a plug outlet, an inverter, a battery and a display system together, so I thought the amateur user-friendly option was the way to go.
All in all, I love the way Casper turned out. It’s not perfect, and I plan to upgrade some things here and there, but I am proud of how cozy and functional my little mobile home is.
A big shout out to everyone who helped me convert this van (especially my mom)! I really appreciate it, because I definitely couldn’t have done it alone!
A few parting suggestions for your own van build:
- Buy a van you can stand up in! (biggest mistake)
- Invest in a top-loading DC compressor refrigerator (not imperative if you’re on a budget, but will make your life easier)
- Use LED tube lights for your lighting- they are very energy efficient and create a great ambiance!
If you have any questions that I didn’t cover here, feel free to email me at [email protected]
Otherwise, feel free to check out the cost sheet/supply list below, and skim through the products I used that worked out well for me in my van.
Van Build Cost Sheet
- Reflectix Insulation – $93
- Reflectix Foil Tape Roll ([email protected]$8)- $16
- Pure Safety Insulation R15 HP AA 15″X93″ ([email protected]) – $75.98
Flooring, Walls, Ceiling, Bedframe, and Storage Units:
- 2 x Sheathing Plywood 19/32 in x 4 X 8ft – $40
- Canyon Yew 32 sq. ft. Wall Paneling 5/32″X4’X8′ ([email protected]) – $75.88
- Luxury Vinyl Sheet for Flooring (Redwood Acacia 12’ x 6’) – $61.44
- Miscellaneous screws, hinges, and metal brackets- $25 (approximately)
- Sheet Vinyl Adhesive- $5.99
- Sterling Oval Single Basin Self-Rimming Undermount Sink (Amazon Warehouse)- $21.56
- Valterra RP800 Chrome Rocket Hand Pump Faucet- $26.49
- GE Silicone II W&D Clear 2.8 oz.- $3.98
- 2 x 5-gallon plastic water containers- $10.65
- 10′ Braided Vinyl Tubing (5/8 O.D X 3/8 I.D. X 10′) – $10.78
- 10′ Braided Vinyl Tubing (7/8 O.D. X 5/8 I.D. X 10′)- $18.84
- 2 x #006 SS CLAMP 3/8″X7/8″ DIA – $1.88
- 1-1/4″ Flex Coupling for CI, PL, CU, LEAD- $5.98
- 1-1/4″X3/4″ PVC Bushing – $1.38
- Fan-Tastic Vent 4000R with Reverse Switch- $159.99
- Koolatron 1.7 cu. ft. AC/DC Refrigerator- $153.59
- Americana by Elite Cuisine 3-in-1 mini breakfast center – $27.37
- Russell by Edelbrock MA-951 Chrome 29-1/2″ Table Leg- $17.34
- Russell by Edelbrock MA-1119 Chrome Exposed Round Table Base- $9.41
- Zinus Ultima Comfort 6-inch Memory Foam Mattress (Queen Size)- $122.76
- Camco 43833 Oak-Finish Cupboard Tension Rods- $4.42
- Upholstery Fabric (Waverly Inspirations- Color: Tile Adobe- [email protected]$3.97/yard)- $15.88
- Eclipse Blackout Curtain Panels- $13
- Tension Shower Curtain Rod- $10
Total Cost of Building Materials, Interior Design & Appliances: $974.52
Solar Electrical System:
- Goal Zero Yeti 1400 Lithium Portable Power Station- $1800
- 2- 160 Watt 12 Volt Battery Charger Solar Panel Off Grid (320 Watt)- $350
- Solar Panel Z-Bracket Mount Kit- $16.29
- Misc. Wires and Adapters- $20
Total Cost of Solar Electric System: $2,186
- Fan install and electrical wiring (@ RV Renovators)- $220
- Solar Panel Installation- $100
Total Labor Cost: $320
Total Cost of Van Build: $3,480
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