Sprinter Van Conversion: Electrical system, AC current...

I'll be the first one to admit it, I over did this electrical system... I just was trying to design for simplicity and ended up with way to much wire ran. It's not the end of the world, I have a few extra wires ran that will probably never be used, their hidden so no harm.

As with the DC power system, I didn't want any part of the electrical system to be connected with factory electrical. The system is 30 amps, with a 100 amp panel box, this gives me the ability to have six circuits. One circuit is a 20 amp receptacle for the kitchen. I have one 20 amp circuit for garage area receptacles and one 15 amp for the entertainment system. There is also a 15 circuit in the lounge area for USB's and receptacles.

I grounded the system to the metal frame to the left of the panel box. The system has worked perfectly so far.

30 amp plug on driver's rear

Sprinter Van Conversion: Insulation

Insulating this rig is a huge job, I looked into the cost of a 600 board ft kit of spray on foam, which would be enough to do the job. That kit cost $575.00 and then you figure the time and materials to prep the areas you didn't want insulation to get and the cost would be about $600.00-$700.00. I got a price from a local insulation company for $1400.00.

So I decided to save some cash and do what others have done. I figure I'll save just in materials $300.00 vs Foam. Like I said "Huge Job..." I put reflectix down against all exterior sheet metal. I used the best adhesive I could find to secure the reflectix to the sheet metal. I could not get to some areas, so I bought cans of Great Stuff and foamed them. There are some areas I did not want to foam, like near lights and wire connections. I'll have to figure something out in those spots

Next, I cut to fit R-15 faced insulation and put them everywhere I could get to. This along with the Reflectix was a pain in the rear because of all the custom cutting and fitting. The foil tape worked great and one large roll did entire project. There are some spots that did not get insulation, areas in between pillars with no access holes, just get everything you can short of cutting metal to get to an area.

Sprinter Van Conversion: Fantastic Vent install

I will have to say, after watching a lot of videos on YouTube about installing these fans, it was pretty easy. With a little planning on top of the van, I was able to position the vent so that I did not have to deal with any of the raised sheet metal parts of the roof.

I made a template out of the cardboard box that the fan shipped in 13 7/8 x 13 7/8. I eyeballed the position to make sure it was straight and then traced it with a sharpie. Yes, I did check it with a tape and it was right on. Drilled four holes at the corners and then cut out the opening with a jigsaw. 

Made sure to cover bottom of the jigsaw base with blue tape as not to scratch the paint. Cleaned the edges up and wiped down the area with a cleaner.

The gasket that comes with the fan is just a white piece of what looks like packing foam. Directions stated to tighten down the screws and wait about 10 minutes before applying caulk. I pre-drilled all the holes and then secured the fan to the roof.

Caulked the screw heads and the flange. I also caulked the inside opening as well Took about an hour from start to finish. 

New project in the works Sprinter Van Conversion

Picked up a really nice 2010 Mercedes 3500 Sprinter Cargo Van yesterday. I have been researching these vans for over a year. Price, fuel mileage, cost, reliability and ability to convert to camping and using as a home base are all pluses with these vans. There is a treasure trove of information online about these vans and I have researched and studied what others have done.


I have a rough idea on my layout but will remain flexible on what works and doesn't and will adjust accordingly. I have three areas that are a must. 1. Must have queen size bed. 2. Large enough storage under bed area (I'll call that area the garage) for two road bikes, two sets of scuba gear, tanks and metal detecting gear. 3. A wet closet for wet suits. I'll incorporate plenty of other storage areas, counter space with room for a refrigerator. 

I plan on wiring for solar power as well as shore power. Powered roof vent, roof rack and back up camera. Micheal and I got started today on stripping the panels off the walls. Up next, we will insulate walls, ceiling and floor. Install roof vent and start the wiring. Stay tuned for more post on this project...