Blue View - What Does a Van Conversion Cost?
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Assuming I’ve already purchased an empty cargo van, the answer to this question is somewhere between $100 and $100,000. On one extreme, I could buy a used mattress on Craigslist for $20 or less, add a couple of camp chairs, some storage bins that could double as a table, and a used camp stove. Then I could build a perfectly serviceable toilet for $20, add a few gallon jugs of water and a styrofoam cooler, and I’d have a minimalistic, but useable camper and still have change for a $100 bill.
On the other extreme, I could deliver my van to one of the premier van conversion companies, ask them to add every conceivable ‘bell and whistle’, and pick it up a few months later. It would, hopefully, be professionally done and beautiful, and I may or may not get change from my $100,000 check.
When we did that first van conversion on our Ford Transit, Blue, we were reasonably pleased with the results. I did, however, go way overboard on several aspects of the upfit - especially the electrical and electronics, and there were several other things we would do differently if there was ever a next time around.
Now we have Blanche, our Ram Promaster. Her upfit was already partially completed when we bought her - some of which was good and some of which wasn’t. We kept the good things, removed or modified the rest, and then began adding to her to make her the way we want her.
As I work on Blanche, I’m discovering that things have changed considerably in the four years since we upfitted Blue. Electronics, not surprisingly, have increased in capability, yet dropped in price. A case in point, solar panels and controllers are much more efficient than just a few years ago, but 20% - 40% less expensive. Another example, the LED puck lights we used in the ceiling. When we bought them for Blue, we got them on sale for $30 each… now they’re $6. On the other hand, many of the materials needed for the upfit have seen a major increase in price. Lumber, for example, is at least 50% higher than it was just a couple of years ago. Eight dollars for a two by four!? Are you kidding me?
If we were starting over with an empty cargo van, however, what would we include, what would we do the same, what would we do differently, and to the point of this blog, what would it cost? For what it’s worth, here are my thoughts…
Note: For brevity, I’ve listed each project and the estimated total cost and labor hours to complete the project. If you’re interested in the details, scan down to the ‘Appendix’ following the end of the blog.
Solar
I’d go with 2 - 200 watt solar panels for a total of 400 watts, coupled with an MPPT type solar controller. We’ve found over the years that no matter how much solar power we have, there will always be times when there’s a need for an alternate method of charging the house batteries, so I’d make sure I could charge the batteries with the engine alternator. For batteries, I’d want a minimum of 300ah.
Total Cost: $1557 Total Labor: 40 hours
Roof Fan
We like the MaxxAir roof fan. It can be left open when we’re driving or in the rain and it never leaks or drips.
Total Cost: $275 Total Labor: 15 hours
Ceiling and Header
I’d insulate the ceiling with 3M Thinsulate (R5), then attach battens to the roof supports. We both like the look of the 6” tongue and groove planks.
Total Cost: $453 Total Labor: 56 hours
Walls
The walls and doors would be insulated with 3M Thinsulate (R5), then I’d use 1/2” plywood, painted.
Total Cost: $831 Total Labor: 54 hours
Floor
Insulate the floor with battens and rigid foam insulation. The subfloor would be 3/4” plywood, and I’d finish it with a good vinyl flooring.
Total Cost: $441 Total Labor: 48 hours
Electrical
The electrical would include an automotive type fuse panel, a 30 amp shore power circuit, a Renogy 1000w inverter with remote, 6 USB charging jacks and 2 GFCI protected AC outlets.
Total Cost: $673 Total Labor: 36 hours
Rotating Front Seats
The front seats can be modified to rotate 180 degrees to face the rear. I’d add this modification and a long footrest/storage compartment.
Total Cost: $700Total Labor: 24 hours
Navigation
Blanche’s backup camera display is small and barely visible on a bright day. In addition, it’s not compatible with Apple CarPlay. We added a Garmin GPS, which we’d also do in a new van, plus add a compatible backup camera.
Total Cost: $365 Total Labor: 4 hours
Armrest
We like the armrest, cup holder and storage bin we added between the seats on both Blue and Blanche, and would do the same in a new van.
Total Cost: $120 Total Labor: 16 hours
Counter and Sink
We’ll need a counter and sink. Under the sink will be a 5 gallon can for freshwater and another for the sink grey water. I’d add a foot pump to pump the water to the faucet.
Total Cost: $490 Total Labor: 40 hours
Diesel Heater
Install an inexpensive diesel heater.
Total Cost: $270 Total Labor: 24 hours
Underbunk Cabinet
I’d build a cabinet with drawers under the foot of the bed - where we currently have bins in Blanche.
Total Cost: $340 Total Labor: 40 hours
Side Window
Blanche has a window in the slider door that slides open and has a screen. It not only helps with air circulation but also greatly increases the driver’s visibility at intersections and when backing out of a parking place.
Total Cost: $465 Total Labor: 20 hours
Bike Mounts
We like carrying our bikes in the garage under the bed. I’d add a pull-out tray that doubles as a ramp and mounting platform.
Total Cost: $320 Total Labor: 18 hours
Fridge
Our favorite is the Whynter 65l chest fridge
Total Cost: $580 Total Labor: 2 hours
Toilet
We’ve been quite happy with our small Thetford cassette toilet.
Total Cost: $150 Total Labor: 2 hours
Miscellaneous Additions
This includes small fans, reading lights, screens for the slider and rear doors, curtains and sunshades for the front windows.
Total Cost: $930 Total Labor: 11 hours
Stuff I Missed
I’m sure there are twenty other things I’ve overlooked or forgotten…
Total Cost: $500 Total Labor: 40 hours
Grand Total
So, what’s the total cost? If my addition is correct, I estimate that it would cost around $10,784 and take about 547 hours to completely upfit an empty cargo van to something we’d feel pretty comfortable in. It’s unlikely that it would ever be totally completed, however… there will always be a to-do list of changes and additions to get done.
BTW - those manhours would have translated into about 11 weeks of time a few decades ago. Now, with naps and other distractions as well as just a general slower pace for this old man, it would probably take more like 20 weeks to accomplish all those tasks.
See you next week…
Appendix
Here’s more detail for the completion of all the projects:
