A Week in Our Van Build Shop

People always ask what actually happens during those 8-12 weeks their van is in our shop. It’s not glamorous, but it’s detailed work. Here’s what a real week looks like for us in Costa Mesa.

Monday: Inspection and Planning

We always start the week by assessing where each active build sits. Right now we have two vans in the shop. One is just arriving - a Sprinter that’s scheduled for a Standard tier build. The other is mid-build on a ProMaster Premium.

The new Sprinter gets thoroughly inspected. We pull it into the bay, pop the back doors, and walk through everything. Are the interior panels in good condition? Any rust or structural issues? Does the factory electrical system work? Are there aftermarket devices we need to remove?

We photograph everything. These photos become part of the client file, and they’re reference material for the weeks ahead. We want to know if there’s existing damage before we start work, so when the build is done, there’s no question about what was our responsibility.

With the Sprinter, we find some rust in the lower door frame - nothing structural, but we’ll need to address it during the paint phase. We document it and flag it in our project notes.

The ProMaster is at the insulation stage. We’re working on the walls, running through each cavity with Thinsulate batts. The driver’s side rear wall has a curved section that’s tricky to insulate properly - you have to compress the material carefully so it doesn’t expand and push against the cabinetry later. We spend time on details like this because a bulging wall ruins the whole interior aesthetic.

Tuesday: Teardown and Systems Work

The Sprinter needs interior trim removed. Factory plastic panels, carpet, factory cabinetry all come out. This is meticulous work because some of these components are integrated in ways you don’t expect. A panel that looks simple is actually bolted through three hidden attachment points.

We save factory fasteners and keep track of what we remove. Not because we’ll reinstall it, but because understanding how the van was put together tells us about stress points and potential water paths.

Meantime, the ProMaster gets plumbing lines run. The fresh water tank mounts underneath, and lines run through the floor into the kitchen area and bathroom. Drain lines need proper slope - at least 1/4 inch per 4 feet, or water pools. We measure as we go. Small slope errors compound over time.

We also rough in the gas line for the tankless water heater. This is copper tubing with proper fittings and shut-off valves. Gas systems need to be pressure-tested before sealing, so this phase includes that work.

By day’s end, the ProMaster’s plumbing skeleton is in place but not yet sealed. The Sprinter is a gutted shell ready for insulation to start.

Wednesday: Insulation and Environmental Control

The Sprinter gets insulated today. Walls, floor, ceiling. We use Thinsulate in walls (R-value that works for van conversions, lightweight, good at managing moisture) and XPS foam rigid board on the floor (rigid, compressible, won’t degrade over time).

This is one of those steps that takes longer than clients expect. You can’t just throw insulation in. Every cavity gets filled. Gaps around structural elements get sealed with foam. Penetrations for future wiring and plumbing get planned out. We install backing boards for screws and fasteners to anchor into later.

The ProMaster’s roof vent gets installed. This is a sealed penetration, which means it requires attention. We install a flanged vent hood, wrap the flange base with self-adhering tape, then add marine-grade sealant. We don’t depend on one layer of seal - redundancy is insurance against leaks.

The auxiliary heater (Espar heater) gets mounted underneath. This is a diesel heater that warms the van on cold nights without running the engine. Exhaust routing has to be done perfectly - you can’t have exhaust anywhere near fresh air intakes or water lines. We run thin stainless exhaust piping through the floor to the rear bumper area.

Thursday: Electrical Rough-In and Cabinetry Prep

The Sprinter moves to electrical work. We install a main disconnect switch in an accessible spot, plan the battery box location, and run conduit paths for future wiring. The goal is to map the entire electrical system before we start running actual wires. This prevents last-minute rerouting and ensures everything is organized.

The ProMaster gets cabinetry started. We build the base cabinet structure for the kitchen, which is where the sink, cooktop, and storage live. Cabinetry is custom made to fit the specific van dimensions and design. Sides, tops, bottoms, interior dividers - it’s all cut precisely.

We use quality plywood and stainless or powder-coated metal hardware. Cheap cabinet materials look good for a month then start warping and squeaking as the van flexes on the road.

Each cabinet section gets labeled so assembly later is straightforward. Doors and drawers are built separately and installed during final assembly.

Friday: Testing and Handoff Prep

The ProMaster’s electrical system gets powered up and tested. Battery bank is connected, breakers are tested, monitoring system is configured. We run each circuit to make sure nothing shorts or causes unexpected loads. All loads are shut off except battery monitoring, so we verify the system is stable.

The Sprinter gets its initial wiring rough-in completed. All the conduit paths are in, all the main disconnect and breaker locations are set. We’re not running power yet, but the skeleton is ready for the next phase.

We also spend time this day documenting progress. Photos are uploaded to the client portal. They get to see their van in mid-build. For some clients, seeing tangible progress makes the wait feel shorter. We always send brief notes explaining what’s happening.

By end of week, both vans have moved through significant phases. The Sprinter is insulated, sealed, and starting electrical. The ProMaster has plumbing roughed in, cabinetry started, and core systems being tested.

What This Week Looks Like in Reality

Behind the scenes, a week of van building involves a lot of unsexy problem-solving. How do you route a water line through a structural member? What’s the best way to mount a roof vent on a curved roof? Why is this cabinet door binding, and how do we fix it without rebuilding?

We’re also constantly quality-checking. Before we close up a wall cavity with insulation, we inspect it twice. Before we seal a penetration, we verify it’s done right. Before we connect electrical loads, we test circuits. Before we hand a van over, everything is tested multiple times.

The pace can look slow from the outside. But a week of methodical, careful work produces a van that lasts. A week of rushing produces a van with problems.

Building With Intent

This is what our builds are about. Careful planning during the design phase, meticulous work during building, thorough testing before handoff. It’s why we’re honest about timelines - this work takes time.

If you want to see the process firsthand or have questions about how we build, get in touch. We welcome client visits to the shop, and it helps to see what actually goes into these rigs.

Check out our work to see finished builds, and if you’re planning your own conversion, we can walk you through every phase of the process.