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Van Build Order: The Six Phases of a Van Conversion

Patrick Beseda
Updated

Where do you even begin? This is the order we recommend for building out a van, from a bare cargo van to a finished build, based on the vans we've built in our shop. Every van and every builder is different, so treat it as a guide rather than a rulebook.

Each phase below lists what to do, the Featherbuilt install guides for that phase, and the parts that go in at that point. For the story behind the order, read The Six Phases of Building Out Your Van on our blog.

Phase 1: Plan and prep the van

After the research and budgeting, it's time to buy the van and get it ready.

  1. Buy your van.
  2. Strip and prep it: remove the seats, factory trim, factory lights and so on.
  3. Decide on a general layout. It doesn't need to be locked in, but decide which side gets water, electrical and appliances, and where any cutouts go.

Plan it with: Featherbuilt Planning Kits for the Sprinter 144, Sprinter 170 and Transit 148 high roof · Van Conversion Budget Sheet

Phase 2: Lay the foundation

This phase sets the baseline for everything else. Some of it can't be done later, or would be very hard to, like running wiring.

  1. Install rivnuts for a rail system, or your chosen furring or structural base.
  2. Cut and install everything that needs a hole in the van: fan, windows, AC, shore power, heater, and the solar wiring pass-through.
    • Planning a roof rack without factory roof rails? Install the rails now, while you can still reach the ceiling.
    • The solar panels themselves can wait. Only the pass-through plate goes in now.
  3. Install seat swivels. Your seats are already out for the heater install and wiring.
  4. Run your 12V and 120V wiring.
  5. Install sound deadener and insulation.

Guides: rivnut installation and match drilling are covered in the wall and ceiling kit guides for the Sprinter · Transit.

Shop this phase: Wall and Ceiling Kits · Van Heaters · Van Insulation

Phase 3: Build the shell

This is when the van starts to look like a home.

  1. Floor
  2. Walls and window trim
  3. Ceiling and overhead lights
  4. Door panels and door trim

Guides:

Shop this phase: Wall and Ceiling Kits · interior trim for the Sprinter, Transit and ProMaster

Phase 4: Lay out the interior

If you've made it through the wiring, walls and ceiling, the next parts are easier, and the most like a home renovation.

Wheel well cabinets

  1. Electrical cabinet. You don't need the whole electrical system in yet, but it's easiest while you can still reach the cabinet, and it's nice to have lights and power while you work.
  2. Water cabinet. You don't need to finish the plumbing either, but run any wiring and plumbing lines to where they'll end up.

Kitchen

  1. Upper cabinets first. They're much easier to install without the lower cabinets in the way.
  2. Galley cabinets. You can fully install them now or just place the base cabinets, then add appliances, countertops, drawers and doors later.

Bed

  1. Bulkhead or divider wall
  2. Bed platform

Guides:

Shop this phase: wheel well cabinets for the Sprinter, Transit and ProMaster · Sprinter Upper Cabinet · kitchen cabinets for the Sprinter and Transit

Phase 5: Finish the interior

It's true what they say: the final 20% can take the longest.

  1. Shelves, tables and cargo drawers
  2. Final switches, thermostat and monitors
  3. Final wiring
  4. Final kitchen install: drawers, appliances and countertop
  5. Final plumbing
  6. Final trim adjustments
  7. Test every system

Guides: door storage panels are in the door panel guides for the Sprinter · Transit · ProMaster, and headliner shelves are in Sprinter · Transit cabinets and storage.

Shop this phase: Water Tanks · Universal Van Parts

Phase 6: Exterior accessories

We save these for last because they rarely depend on the interior. The exceptions are exterior lights and a powered awning, which need their wiring run in Phase 2.

  1. Roof rack and solar panels
  2. Side steps
  3. Rear door ladder or tire carrier
  4. Awning

Any time

Window covers and bug screens don't depend on the rest of the build, so they can go in whenever you like.

Shop by van

Sprinter parts · Transit parts · ProMaster parts · Universal parts

Need a hand?

You can do this, and we're here if you get stuck. Email support@featherbuilt.com or send us a message from the chat on featherbuilt.com. Photos of where you're stuck help us answer faster.

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