DIY Sprinter Van Build

Building Your Next Adventure Van

The entire process from start to finish

Building a sprinter van has been one of the most exciting challenges I’ve taken on. As someone who loves being on the move, creating a home on wheels was the perfect way to progress my sport and love for travel while saving money on rent in one place. In this article, I’ll share my personal journey through the DIY van build process, from sourcing the van to figuring out the electrical system and making it feel like home.

This article was written in partnership with technical contributor Dean Tucker at Funtrail West, a custom van builder in Reno, NV.

Sourcing

Sourcing the right van was the first big hurdle. I knew I needed something reliable but I didn’t want to blow my entire budget on the base of the van and wanted to focus on how I would build it to suit my needs. I scoured Craigslist and Vanlife Trader, another great resource for used vans. I set up searches and checked them almost daily until I found one I liked. If you’re going this route, patience is key! I also kept an eye on other platforms and even considered local dealerships. Ultimately, I went with a used van that was mechanically sound and within my price range. This even meant flying to where I was meeting the seller to pick it up and then driving it back to my area, but you get so many more options when you expand your search range.

Assessing Your Needs

Some other considerations could be budget, how many people you’ll be traveling with and if it’s full time or part time.

Before diving into the build, I had to be realistic about what I needed versus what I wanted. My partner and I are both runners, and we live in our van full-time, so the space had to work for two people (and all our gear). We also needed storage for off season clothes and other necessities, and some flexibility for workspaces since I primarily work remotely.

One big thing to consider is your power usage. For us, being off-grid was important, so we made sure to factor in energy usage for things like charging laptops, running lights, and making sure to have extra incase we needed to upgrade in the future without running our batteries too low. Ultimately, I planned for longevity and accessibility, and could have made it more low cost but would have sacrificed on some components that were essential for me to live comfortably on the road.

Cabinetry

Cabinetry was a fun part of the build because it really helped transform the van into a livable space. We needed smart storage solutions for our gear, and I decided to go with Timber Van Kits for their high-quality cabinets that are designed specifically for van builds. Not only do they look great, but they’re also lightweight and easy to install, which is crucial in a van where every pound counts.

To ease the building from scratch, I was able to select exactly what I wanted and went with the Overhead Cabinet Kit, a DIY Kitchen Galley Kit for my kitchen setup which included a refrigerator, sink, fresh water and gray water tanks; and a Headliner Shelf for extra storage.

I needed enough storage for full time living, with clothes for two people. I went with a two door cabinet over the kitchen for pantry items, and a three door cabinet setup over one side of the bed for all our necessities. We got to stain and sand them ourselves to get the perfect look that complimented our build.

Plumbing

When it came to plumbing, I had to decide whether or not I wanted the luxury of a shower or hot water. Since we often stay in places with gym access, I chose to skip the built-in shower, and a hot water tank, but compromised and included a shower hose at the back for quick rinse offs. A valuable lesson here for a prospective DIY is the cost and complexity of hot water. You need to choose propane or electric, and if a larger electrical setup, battery and inverter is worth it. Since we had two 6 gallon tanks under our sink, I kept one for draining the gray water from the sink,tand increased the amount of our fresh water supply to a 35 gallon water tank installed in the back under the bed. This setup has really suited my needs and I’ve had enough water to last a week when it’s just one person cooking and living in the van.

Alternatively, you could set up a drainage system for gray water that drains  directly under the van. There are some pros and cons to this, such as needing to use bio based soap and making sure you’re in an area where drainage wouldn’t be an inconvenience or impact the environment, but it eliminates the need to take out and empty a heavy gray water tank.

I fill my 35 gallon fresh water tank using a gravity fill water inlet in the back, which makes hooking up to a hose and filling the tank easy and versatile.

Electrical

Designing and installing the electrical system was definitely the most intimidating part of the build for me. Thankfully, I found a knowledgeable and experienced resource at Funtrail West. Funtrail West specializes in designing and building custom adventure vans for off-grid van travel and living. Dean Tucker, the owner, will work with DIY folks like me who are in need of specialized skills and resources. Dean agreed to help me work through my requirements for amps and watts. We were able to use many of the parts I had already purchased and revise the system design to help me achieve the off grid living I was looking for. Funtrail West specializes in all areas of van building and helped me reimagine some of my interior by relocating and designing some additional components.  

My system includes two 100 Ah Lithium Ion batteries, a 200 watt solar panel on the roof, a solar charge controller (an MPPT), a DC-DC charger to charge the batteries from the alternator, an AC-DC charger to charge the batteries from an AC outlet, a 2000 watt inverter to power everything from our 12v lights to our 120v electronics and appliances. Dean mapped out my needs and energy requirements, and provided a buffer with what I wanted to do and the ability to add on and expand the setup in the future.

Sanitation

Living on the road means thinking ahead about sanitation. While many people don’t feel like this is necessary and there’s always nature or public bathrooms, I went with a composting toilet from Trelino. The toilet is compact enough to fit under a step that Dean at Funtrail West built, and I haven’t regretted it. It’s compact, doesn’t smell, and doesn’t require water. For us, this has been the easiest and most sustainable solution, especially when we’re parked in remote locations for long periods or in residential areas where having a bathroom close by is really convenient.

There are many great options available and I recommend doing some research into what would work for you. We empty ours regularly but there are others that vacuum seal waste so you can dispose of it anywhere, but those are often bigger and need an electrical hookup.

Internet

There are pros and cons to having WiFi on the road. For us, especially with working remotely, it was essential. There are lots of different options ranging from a simple personal hotspot, to portable routers and even Starlink. Part of finding the best option is assessing your needs and seeing what would best fit your work schedule and budget. I started with Solis, a portable WiFi hotspot that’s easy to use and works in most places. It has worked well for sending emails and writing updates, but depending on the network it can lag on Google or any streaming and video calls I might have. The way this router works is by connecting to the closest and strongest internet tower and transmitting a signal to your space. There’s the initial cost of the router and then a monthly subscription fee, with varying levels for how much data you’ll need.

I’ve had some issues with Solis finding the best connection, but the customer support has been responsive and can manually change your router to the strongest network in your area. This was my best bet for a more budget friendly option that still gave me internet access in most areas.

There’s also WeBoost which is a brand making signal boosters designed to improve cell phone reception, particularly in areas with weak signals. In van life setups, a WeBoost device can enhance your cellular connection, making it easier to use mobile data for internet access. It works by capturing weak signals outside the van, amplifying them, and then rebroadcasting the stronger signal inside the van. This can be helpful in remote areas where cell service is spotty, allowing you to get better data speeds for tasks like streaming, browsing, or video calls.

Another popular option is Starlink. This offers high-speed satellite internet, ideal for van life in remote areas where cell service is weak or unavailable. It provides global coverage with speeds up to 100-200 Mbps, making it much faster than mobile hotspots. However, it comes with a high upfront cost of around $600 for the equipment and $150 per month for service. The bulky dish needs clear sky access and storage, which can be tricky in some environments. If you’re often off-grid, Starlink can be worth it, but if you have decent cell coverage, a WeBoost with a hotspot or a Solis device with a monthly plan is a cheaper alternative.

We may consider it for future off grid living and travel for the many benefits, but right now the device we have fits our current lifestyle where we’re not working full time on the road in remote areas.

Takeaways

Building this sprinter van has been a rewarding project that’s given me the freedom to live and explore on my own terms. Every challenge, from sourcing to wiring the electrical system, taught me something new. Now, I have a home that reflects my lifestyle and supports my adventures. If you’re thinking about building your own van, trust the process—it’s worth every step!

 

You can find more of Ella’s articles here and follow along on her journey through @ellasuring on Instagram.