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All great projects start with a plan, and that we had. We were supplied with pretty detailed layout and design of what the finished custom van conversion was to be.

We start out by thoroughly insulating the interior with a combination of Lizard Skin Ceramic and Lizard Skin Sound Control spray-in insulation along with 1.5" thick rigid foam sheet insulation. The van is dead quiet and maintains temperature quit well.

Wall and ceiling panels were constructed out of 1/4" birch plywood and covered with spec'd materials. Framing of the bathroom/shower taking place. All framing and structures of the Sprinter Van were fabbed with aluminum to help keep down weight and maintain strength. 

The stainless steel shower pan we had made didn't come with drain provisions. We made a press die using some steel sheet stock so that we could have the shower drain recessed.

The recessed drain in the shower pan turned out perfect.

Aluminum framing and supports taking shape for the nearly queen size bed complete with headboard.

An Onan propane generator was added under the Sprinter van to power up the Dometic rooftop HVAC unit and to keep batteries charged. We also found room for 15 gallon grey water tank, 28 gallons fresh water & a 12 gallon propane tank under the van.

To further versatility of the van, we added a front receiver hitch. Mainly so client could haul his Grom motor bike around.

A one piece roof rack was constructed out of aluminum and then powder coated black. This gave us attachment points for LED light bars, the overhead awning and solar panels along with some additional storage options accessible by the attached ladder.

Dometic dual burner stove and sink unit integrated into the galley cabinet along  with a 4.2 cubic foot Vitrifrigo stainless steel refrigerator/freezer. 

We finished off the galley with a glass tile backslash. The cabinet extends from front to back with a ton of storage available.

The overhead galley cabinet offers more storage and a convenient location for light switches, HVAC controls and on board power management systems.

More overhead storage cabinets, under cabinet LED lights, vent window, seating for two, receptacle socket in floor for removable table.

A whole bunch of electronic goodies stashed beneath the bench seat. Two 480 amp agm batteries, 3500 watt inverter charger, solar controller, wi-fi hotspot, Apple TV, transfer switch and all system fusing.

Out the back of the van there are three storage drawers, a pull out bike tray, propane on demand water heater, Park Tool bike work stand, hook ups for out door shower, propane BBQ and on board air compressor system.

The spare tire was relocated from under van and onto rear bumper along with an additional storage box and dual bike racks.

Top down view of completed roof rack with 200 watts of solar, vent fan, HVAC unit and an awning.