Ultimate Guide to 4WD Van Conversion

A 4WD van conversion is a great way to seamlessly transition into a nomadic lifestyle and roam around in distant places. You can DIY convert a 4WD into a camper van by starting with cleaning and measuring the interiors to make a design layout, insulating and installing the walls and floors, and ventilating to ensure a supply of fresh air. You also need to install an electrical, water, gas, and heater system and finish by building the exterior.

When it comes to making your van life more comfortable, electricity is important, and most prefer solar panels. But these are expensive, and if you feel the same, you can invest in portable and reliable solar generators. Jackery Solar Generator is one of the best out there, and thanks to its battery capacity and safety, it comes as a viable companion for campers.

Key Takeaways

• A 4WD camper van is better than 2WD and AWD vans due to its ability to deliver comfort even on off-road and unpaved locations and handle any weather condition.
• When choosing a 4WD for van conversion, you must consider factors like size, features, costs, amenities, parts, and repairs.
• A 4WD van conversion requires a budget of around $2,000 and $97,000+, depending on the van size and the amenities you want to include.
• The steps to convert a 4WD van include cleaning and measuring, designing the layout, floor and walls, insulation, ventilation, building a frame, electrical, water, and gas system, and building the exterior.

Introduction to 4WD Camper Van

A 4WD camper van is a recreational vehicle that allows adventurers and avid travelers to navigate through off-road trails and rough terrain, which traditional RVs and camper vans might not be able to manage. These serve as your home away from home when traveling, with built-in amenities like kitchens, beds, and bathrooms. Here are some other benefits of these vans:

• Off-roading: These camper vans can handle rocky roads, uneven terrains, and steep slopes. You can also take them off-road and explore remote areas.
• Weather: 4WD camper vans can tackle inclement weather conditions like rain, snow, gravel, and mud.
• Comfort: Irrespective of off-road or unpaved locations, you won’t have to compromise with the comfort. And with basic amenities of home, you can relax anywhere you wish.
• Safety:  4WD camper vans improve traction in potentially challenging driving conditions.

Now, the question is if 4WD vans are a better option than 2WD and AWD. To understand that, let’s compare these.

2WD, as the name suggests, uses two wheels instead of four to power the vehicles. These are a bit smaller than 4WD vans, thereby being lighter in weight and requiring less energy to move. Besides, these offer faster acceleration, better gas mileage, simpler handling, and easier maneuvering when on roads. Unlike 4WD, these suits are best for normal road use and towing cargo on a short distance.  

On the other hand, AWD is almost similar to 4WD camper vans, where engines power four wheels at the same time. It’s drivable on all surfaces, including pavement. The only difference is that AWD vehicles don’t have a “4-low” setting, making them less capable in off-road settings.

If you’re still confused, here’s a table detailing the pros and cons of each:

What is 4WD Van Conversion?

A 4WD van conversion is a process where four-wheel drive capability is added to a van. As mentioned earlier, 4WD vans offer better traction and are easy to drive through rough terrain and slippery conditions such as ice, mud, rocks, and snow.

The reason is that when a van is shifted to a 4WD mode, both axles get power all the time. Irrespective of the terrain, engine torque is maintained on at least one front and rear wheel, resulting in more traction. With a 4WD conversion van, you don’t need to think twice before traveling to some serious off-road terrain and camping in remote destinations.

What to Consider When Choosing 4WD for Van Conversion

Converting into a 4WD camper van requires a lot of research and pondering, and you can’t go for the cheapest or one that looks good on your social media post. Here are a few things to consider before investing in a 4WD:

Size

People are often tempted to buy the biggest camper van for apparent reasons: ample space, comfortable living, and plenty of amenities. However, you might regret it in the long term. Besides its advantages, a large camper van has challenges of its own, such as difficulty in parking, maneuverability, and handling. It’s thereby crucial to select a size that suits them the best.

Your van size should depend on the size of your family, whether you need to park it in urban areas, go on short/long road trips, or carry specific equipment. Understand that these vans are available in the following sizes:

• L1H1: It’s the smallest, where you can get a bed and a few cupboards, but there isn’t a standing space. But the best part is, you can take and park it anywhere.
• L1H2: Compared to L1H1, there’s more space inside, and importantly, you can stand. So, you can accommodate a few more things in it, but give up on underground parking spaces with standard height barriers.
• L2H2: It is similar in height to the previous but longer, making it more livable. Forget underground parking; the van might hang outside a regular parking space, but in most cases, you can get by.
• L3H3: It’s both taller and longer than previous sizes, so you can be a bit creative about the layout and add amenities like a kitchen, bathroom, etc. But your vehicle no longer fits into the standard parking space.
• L4H3: It’s the largest of all, with plenty of space, but handling and maneuvering get a bit tricky.

Features

Think about the kind of van options you want in your camper van, for example, if you need to drive it on off-road terrains and whether you need a van with a built-in GPS. Other than that, consider whether the van should be automatic/manual, in-built diesel/petrol, and if the seats are heated/AC. Make a list of the features you seek from a van before you start shopping around.

Amenities

When you go for a camping weekend at a decent campground, all you need is a fire pit and a lovely picnic table, and you can go on having the best time. The issue, however, arises when you decide to go on a full-time van life, so you must decide on the features to include: dining table, kitchen, bed, toilet, and shower.

Based on these decisions, select an ideal van size, budget, and preference, and decide whether you will make it yourself or hire a professional.

Costs

It all comes down to how much of your budget you have for 4WD van conversion. Purchasing feature-laid large vans with several amenities can be expensive, and if you don’t have the necessary budget, it’s time to compromise.

Simply consider this: You must spend around two-thirds of your budget on the vehicle and the rest on conversion costs. You need a good-quality van to start with, and there’s no point in spending thousands of dollars on converting a van that will last two to three years at most.

However, you can save some money by opting for an older, used van. You can often get a good deal on these, and if you have trouble locating one, look for alternate financing options. Using recycled materials also saves a chunk on budget, so it’s also worth considering.

Parts & Components

Next, decide what transmission, motor, axle, and transfer case you want. It depends on the type of van you purchase and where you want to travel.

Transmission & Transfercase: Transmissions are of two types: automatic and manual. Automatic transmissions (like C6 3) and cast iron transfer cases are sturdy, reliable, and cheaper to repair if they break. This isn’t the case with manual transmissions, as you might get into trouble hooking up the clutch linkage if there isn’t one already.

Axle: It’s recommended to stick with E250 or E350 as the rear axle, as the shock mounts and spring pads are in the right position and are more reliable in off-road terrain. For the front, check for the F250HD or F350 type axle, as they can handle a lot of weight and push the vans at high speed on rough roads. Or you can opt for a solid/straight Dana 44 axle and left springs if you need to spend less.

Steering: Take a test drive on the van for around 30 minutes and take a half-turn right and half-turn left to check if handling is easy and there isn’t any noise.

Repairs

When you take a test drive, try listening to the engine to see if it’s running smoothly or making any unwanted noises or sounds. Also, carefully inspect the floor, walls, and ceiling to detect rust or leaks. These are repairable, but the more they are, the more time and even the budget they take. It gets tougher if you already have a budget laid out.

Now that you understand the things to consider when choosing a 4WD for van conversion, here are some of the top models to select from:

• Sportsmobile Classic: These are probably the most popular camper vans in the market for the right reasons. It’s built on Chevy Express or Ford E-Series van chassis, is rugged and capable, and is available in multiple sizes and configurations. They offer customized campers, or you can undergo a Chevy Express van 4WD conversionto the van.
• Ford Transit: It’s one of the most popular and top-selling vans in the USA, courtesy of its good carrying capacity, affordable, and its parts are easily accessible.
• Mercedes Sprinter: It’s a high-quality van that has become heavily popular for conversion due to the availability of multiple size options and a spacey interior. But it’s pricey, and its parts are difficult to access.
• Fiat Ducato and Peugeot Boxer: These are solid boxy vans with lots of parts and maintenance availability, and there are many options to choose from. The only negative is that they’re available in FWD only.
• Vauxhall Movano: It’s a large van with ample open loading space to become a self-contained living area. Furthermore, it’s available in different sizes, roof heights, and wheelbase options, and it is suitable for many layout options.

Other options to consider are the Renault Master, Volkswagen Crafter, and Mercedes Vito.     

4WD Van Conversion Cost

The cost of converting a van into a 4WD camper varies with the changes you make. But to give you a general idea, converting a small van with basic amenities costs you between $2,000 and $12000, and that of a mid-sized van is between $26,800 and $36,800. On the other hand, taking up a large van with ample living space might cost you between $62,000 and $97,000+.

That includes the price of a van, which, if used, costs between $9,000 and $25,000 and, if new, between $25,000 and $85,000.

Here’s an overall breakdown of the conversion costs:

Whether it’s cheaper to buy a camper van or build a conversion depends on what you want to buy or build, and the options are practically endless. A fully furnished Fort Transit starts at around $45,000, and its all-wheel drive option starts at $50,000, which can get higher depending on the features and amenities.

There’s no turning around that 4WD camper vans are expensive, but with conversion, you have the flexibility to build the interior and build a less costly van if needed.  

How to Convert a 4WD Van

Now that you’ve decided to convert a 4WD van and don’t have enough budget to hire a professional, here’s a list of steps to follow:

Clean & measure

If you’re investing in an old van, chances are you need some initial work cut out before adding anything new. In many cases, you need to rip up the seats and other components. Use a vacuum, carpet cleaner, bristle, or other useful equipment to clean the insides. It might not be the most glamorous job and might take a day or two, but it’s probably the most important one.

As you clear the insides out, measure the van to determine the type of renovation you will make and the amenities you can fit inside. Also, take measurements of the wheel wells and windows.

Design layout

Now you have the measurements, it’s time to design your camper van’s layout. Determine what’s crucial to include, and if you’re tight on budget, focus more on your needs than wants. Decide the type of bed, location of the kitchen, type of storage, how big it will be, electronics, and whether you need a desk and a toilet. Once you determine the top priorities, think about the space each element can take and where you can place each.

Start drawing some basic plans using the measurements you took to get an idea and start building on it.  

Insulation

Insulation is probably one of the most important aspects of this van conversion guide, as living inside gets tough when the temperature gets very cold or hot. Although sheep wood and other ecologically responsible materials seem a good idea, they are known to absorb water, which is a strict NO for your van.

Instead, use Xtratherm insulation material, which is lightweight, flexible, affordable, and easy to cut. Besides, they don’t absorb water and are great for heat and sound insulation.    

Floor & walls

Now that you’ve placed the insulation, measure and cut wooden panels of around 10mm thickness, paste them by gluing wooden strips on the insulation, and screw the panels to the strips. Finish it with vinyl, as it’s cheap and ensures no fluids or dirt enters the floor under the wood. Then, for the walls, add wooden sheets over the insulation. It allows you to attach the wall panels easily to the planks.

You will need power tools like electric cutters and drills to cut the cardboard, and depending on an electric outlet can be challenging and expensive. You can invest in Jackery Solar Generators to power your tools and other appliances anywhere for hours.

Ventilation

Sleeping in a steel box without any fresh air isn't fun; amongst all available solutions, a roof ventilator is the most common. Carefully measure, drill, and sow the roof, and follow it up by putting the vent and sealing it off. Also, you can cut some windows to ensure a fresh air flow inside the van. You’ll need power tools here, and Jackery Solar Generators can be an ideal companion for charging them.   

Build the frame

At this stage of converting the camper, lay the structural foundation of everything you build onto the walls. This way, you get an accurate idea of where everything, including cupboards, work surfaces, bed, lights, and control switches will be. If you’re confused about how the frame holds, try adding as many support beams to make them as solid as possible.

Electrical system

When converting a 4WD van, it’s crucial to be self-sufficient, i.e., a solar panel and electrical installation. In this way, irrespective of where you are, and as long as the sun is there, your appliances will be running. But these are a bit expensive, and installation requires expertise, so consider investing in Jackery Solar Generators. These are portable, reliable, affordable, safe, and power most van appliances for hours.  

Water system

Next, decide on where and how to install the water system. Typically, you need a water tank to store fresh water, a pipeline to dump water from the kitchen and bathroom, and a water heater for showering.

When installing greywater outlets, consider that regulations for disposing them vary from state to state. For example, in New York state, you must treat and dispose of the wastewater from domestic activities except for toilet usage through an approved septic system or public sewage treatment facility. So, take note of it and modify it accordingly.

Gas & heating system

You’ll need a gas system in your kitchen to cook your everyday food if you stay in the van full-time. Find a reliable gas engineer to install the gas pipeline for your camping van, but make sure he has previously worked on such mobile houses.

Exterior building

The exterior phase of your camper van encompasses the changes you need to make: installing skylights and windows, roof racks, and other inlets. You can also start with this, so it’s much easier to cut holes into your van before you’ve covered it with insulation and cladding.