In June 2020, during the COVID-19 pandemic, we decided to do a DIY van build. We purchased a 2020 Ford Transit 250 AWD with a long (but not extended) wheelbase so it fits in a normal parking spot and a medium height roof since we aren’t NBA players.

We rented an amazing workshop near our house for 6 months which allowed us to store the van and all our tools, supplies and equipment for the majority of the build. This shop was up-fitted with a swamp cooler which made the 100+ degree days of the Southwest summers bearable, just barely.

We were pushed into doing a DIY van build as many of the reputable van builders we were interested in had 2 year waiting lists and we are not that patient. We did not want a traditional RV, trailer or camper for a variety of reasons. Our new van build is far from perfect and nobody would ever call it professional-grade, but it is safe, reliable and designed completely for our specific needs. We know where every wire, screw and connection is in case (when?) repairs are ever needed. We designed some items within only 1-2 mm to spare so we could maximize our living space. There was a necessity to learn new skills during this build so we are now master “plus-nuters” and master “electrical wire crimpers”, but master electrician and carpenters we will never be. We have cut more holes in the sheet metal of this van for windows, fans and pipes than we ever thought we would be comfortable doing.

Our design for the van was based of our experience owning a 2012 Tiger Adventure Vehicle and an overlanding-equipped 2016 Toyota 4Runner. Our priorities for this van build were: a dinette style seating area, a bed we could sit up in, cross-ventilation, a refrigerator with a freezer which could fit more than an single ice cube tray, composting toilet, deep sink and storage inside the van for a bike (or two). We wanted a van that could handle driving down dirt and Forest Service roads but still could be easily maneuvered through busy downtown city streets. Folks raise their eyebrows when we tell them we have no inside shower, no hot water, no inverter and no solar. We have only a single Battle Born 100 amp hour LiFePO4 battery, but that will probably change to two batteries once we start really using the van as this was the bare minimum power we needed by our calculations and projections. These decisions and omissions were all intentional and based off our style of travel and we have no regrets. Is our build and design choices for everyone? Nope, but they were right for us.

Our van build was almost entirely DIY with the exception of the installation of the heater, a suspension upgrade and tinting of the windows. The Webasto heater required dropping the fuel tank and adding an axillary fuel line and this was above our paygrade in skills. The suspension upgrade was probably doable with lots of learning and effort on our part, but for the sake of time and our marriage we had the professionals do this, too. We could have never made the window tinting look this good, so it was low cost and high value upgrade.

So, is the van ready for prime time? Nope, but we are leaving anyway on a month long Tour de Colorado road trip to escape the heat of the SW US. The the van is 100% functional. Electricity? Water? Toilet? Ventilation? Cooktop? Refrigerator? Sliding sleeping platform? Check to all of these items. What is missing is the a lot of the finish work including upper cabinets, upper wall panels and a swivel passenger seat.

Introducing Tofu, our latest adventure rig. We hope to have many great adventures in the coming years in the US, but eventually Europe, too. There are sure to be both highs and lows and we hope you will follow us on this next journey.