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We have built lots of demo vans in the past, all of them built with a specific purpose. We thought we would build a van that is similar to our past builds, but take it up a few levels and introduce new technology to build to this date the best possible modular build for a family that would fit them, sleep them comfortably, seat them comfortably, be super flexible in design, and grow with them as the family grows both in numbers and size. :)
Why a Crew Van Trim?
Safety, it has features for safety not on a cargo van like a crash bar in the slider door. Comfort, only the crew or passenger van has a heater duct for the rear. Cost, a crew van has some trim that is not available with a cargo van which makes the build less expensive and easier to do saving money on the build.
An added benefit is its "turn-key" even if you don't build a van, it already has seats, most of the walls, and a headliner. Expect to pay into the mid $80-90k range for this type of van today at the dealer.
An advantage of 2022 and newer models with the 4-cyl engine and new transmission is they are officially approved for B20 Bio Diesel fuel use all the time. In some markets like California, that is super important as 70% of the diesel is B20.
Challenges
Make the seating flexible to fit 2-8, sleep up to 6 full-size adults, and enable 4-season camping for all temperature conditions, from desert to the snow in the mountains. Flexible enough to make it fully self-contained for BLM camping or when facilities are not available.
Seating
This build is special, we wanted to provide the ultimate seating solution- captains chairs to fold-down bench seats that would make another full-size bed. The Smart Floor we designed has special custom track spacing to fit the new Bench Seat or individual chairs.
You can add swivels to seats to do unlimited seating layouts and with 4 different seat options available for Smart Floors you have unlimited options. We set up this van for captain chairs on either side or down the center of the new slidable bench seat to sit/sleep even more if that layout is preferred.
Example of how flexible the floor can be, click on the button above for more info.
Smart Floor is a modular aluminum floor that is custom-made and DOT-approved. L Track is milled into the flooring. Trim and flooring also have to be put on to finish the floor. In this particular van, we even added insulation into the channels.
Why a Pop Top
Most builds don't fit people and gear. Every time you load a van with all of your stuff for your family and seat 4 or more...it just doesn't fit well if at all. The Instagram and Etsy photos never show vans with people and gear...you have to move half of your stuff just to go to sleep.
The idea of having a campervan is to make your life more comfortable, eliminate camp setup, and allow you to hang out inside when conditions outside are not comfortable. You really can't do this without a pop top.
A Pop and rear platform bed gives you two places where FULL-SIZE adults can sleep very comfortably without moving any gear. Isn't that the purpose of the van to begin with? This pop top has many upgrades, booster lift struts, paint match, artic insulation package, mounting rails,
Maxx Air Fan, solar panels, Fiamma Awning, and a custom Halo Rack system that protects the top and allows a more secure mount for the Awning. (looks good as well)
Does your van look like this? Where do you sleep?
The area above inside looks like this, access from inside so you are out of the weather, climbing up a ladder to a tent on top of your van when it raining and dark is not ideal nor comfortable
True 4 Season Camping
We wanted to build a van that could handle a wider range of temperatures. A fan vent is a must-have to move hot air out of the van so you can sleep and is usually more than enough when it's warm, but not hot. The Espar D2L heater we used in this build with a high altitude sensor (not available with other brands) allows you to be very warm and dry in colder conditions. It only uses a quart of fuel to run all night.
However, there are times when we have been traveling and it's 90 degrees at 10 PM...it can get a bit uncomfortable. :) So we added an AC unit on top of the Pop Top...super unusual. The top has to be reinforced to handle the extra weight and AC units use HUGE amounts of power.
To balance this out we not only put in a state-of-the-art power system to power it, but also put in a high-end 48v AC that uses the least amount of power to cool the van down, specifically a Nomadic 48v X3... next-gen technology using 1/2 the power of most AC units. It's super light, compact, and because it's 48v...super efficient. This will enable the AC to run as long as possible.
If used for long periods there is even a shore power hook-up built in the electrical system.
Nomadic 48v X3- next gen AC
There is a lot on this roof...super tricky, Zamp Solar Panels, Starlink, Maxx Air Fan, and Roof AC!
The heater is under the passenger seat, has easy access for service, and is out of the way in the van keeping it free for gear storage
Power System
You don't need a large power system if you are just running a fan, heater, fridge, and DC outlets for a phone or a laptop. When you add AC, it's a totally different story, or if you want to run large power items like hot plates, microwaves, hair dryers, e-bike charging, and coffee makers as well. AC however like your home can greatly affect the power needed to run it, even for a day or two.
We decided to install the new ECO FLOW 48v MODULAR van/RV-specific 10kw system in this van. (~833ah) This is more than enough power to run the AC for a few days and meet all of the other power needs. Having solar helps replace some of the electricity used (not all of it) and having alternator charging and shore power you will have many other ways to charge the huge battery bank. 48v makes it super efficient.
Plug and play modular power system makes it super easy to service. This is a next-level power system to meet the demands, especially for the AC. You also have a shore power hookup for unlimited run time of the AC as well.
Ecoflow modular power system. Clean, modular, and takes up minimal space.
Make the Van Quiet and Cool/Warm
We take care to make our vans quieter, warmer, and cooler by extensively insulating and sound-deadening the van. (yes you need both to get maximum results). We did all this van's walls, doors, and even the floor. This van is as quiet as my wife's Honda Pilot and the factory AC and heater work much better when we do this. It's an insane difference.
Ultralight sound deadening in the slider before we put insulation over that.
Insulation and sound deadening mid-process. We like using Dynamat and 3M Thinsulate, these are premium materials. They cost a bit more, but the end result is superior. This is a photo where we are mid-way in the process and doing electrical work.
Increased Stability and Performance
For this van we installed an Agile Offroad RIP kit, this isn't just some shocks, this is a complete suspension upgrade including rear springs and front struts. This greatly reduces roll and sway off-road and with high winds. It drives like a totally different van. In addition, we also did a drive shaft upgrade that eliminates the possibility of the front drive shaft pulling out.
Upgraded Wheels
Black Rhino 17" wheels and 265/70/17 BFG Tire size are used to get maximum clearance for debris and snow. We find this is a very functional upgrade and of course, it looks great. You can go larger, but you lose functionality reducing clearance. You do have to modify the fenders to fit these tires/wheels.
We also unlike other vans modify the rear and gain an inch of clearance, a regular "Fender kit" does not do this.
You just can't bolt these on. A Fender mod is needed.
Outside Shower
We added a 25-gallon water tank and an outside shower. Great to rinse off dirt, and bikes, or carry extra water.
Storage
The biggest problem in a van or even a home is storage for gear. We really addressed this issue with a ton of storage, all removable. The semi-rigid Van Essentials storage cabinets are semi-rigid and have tons of pockets outside and even have a shelf. They are much larger than wood cabinets and you won't cut your head when you bump into them.
We even added a rail to mount even more removable storage under the bed. This still leaves your floor open for other large gear. Not only does this van have a crazy amount of internal storage we even put more outside with large aluminum boxes - great for dirty stuff, propane, or other items not wanted in your daily driver camper van.
Inside Modular Storage
Rear Outside Storage
Additional Removable Storage under the bed, still keeping the floor clear!
Front Dinette
Instead of putting a dinette in the back where your gear would fully bury it, we put swivels in front and a league table so that you can quickly have a place to hang out, eat, play board games, or even make a cooking area.
Example of what additional seats can do
Modular Bed, Removable bed
We used the Adventure Wagon MOAB bed and a super deluxe mattress. Almost King size, this system removes in seconds, fully height adjustable and stackable system. It is very lightweight and the three panels allow for increased flexibility in interior layout options. It really is the "Mother Of All Beds".
We feel that this type of bed is one of the best for a modular camper van build.
MOAB Bed without mattress
The van totally empties into a cargo van quickly.
Extended Travel Range
An XL water tank and 41-gallon gas tank allow for extended travel.
Modular Interior
This daily driver camper van with modular seating allows you to set up the van in different configurations as needed. Components such as a compact sink (not inc), fridge, or cassette toilet can be placed anywhere in the van to dial the camper van's daily driver for any travel situation.
The 144" is tight, but it's a length that fits in a regular parking spot. The modular camper van interior allows for maximum flexibility.
An example of how an interior can be set up with a sink and fridge.
Sound/Audio
We did not forget a great sound system for those long road trips. Not only did we relocate the XM radio antenna, we incorporated in the factory MBUX head unit a Kenwood 5 channel Class D amplifier, and 10" subwoofer, added rear Kicker speakers, and upgraded the front door speakers and Kicker speakers as well.
The insulation and sound deadening make this all sound really nice, but not overpowering. We hide everything to keep the interior clean. Even the subwoofer is designed to be family-friendly, it can be moved around the modular camper van, stood on, kicked, and not damaged.
We don't put it under the front seat...that is a horrible idea for your passenger sitting on that seat.
Video Overview
Beautiful