Recreational Vans

How much does a van conversion cost?

The real price ranges for van conversions

A full cost picture starts with two numbers: what you pay for the van and what you invest in the conversion. The base van can run 25k to 80k depending on age, mileage, trim, and whether you choose a Transit, Sprinter, or Promaster. Conversion costs stack on top and vary by scope, materials, and professional labor.

Essential adventure build: 15k to 40k for insulation, flooring, a simple bed platform, basic cabinetry, vent fan, minimal power with a small lithium battery and inverter, and a compact water setup.
Mid tier custom conversion: 45k to 90k adds larger lithium storage, solar, shore charging, a more finished galley, hot water, diesel heater, swivel seating, modular storage, and multiple vented windows.
Premium off grid rig: 100k to 250k plus multiple 200Ah to 600Ah lithium batteries, 3000W inverter charger, 600W to 1200W solar, 12V air conditioning, smart floor with DOT seating, custom cabinetry, composite shower, onboard monitoring, suspension upgrades, roof rack, awning, and exterior armor.

Labor is the multiplier. Professional conversions typically require 300 to 800 shop hours, influenced by custom metalwork, complex electrical, and interior finishes. Shop rates commonly land between 90 and 175 per hour. Materials have climbed in recent years, so allow a healthy buffer for electrical components, birch or composite sheet goods, and specialty hardware. Finally, factor in registration changes, insurance adjustments, and a post build shakedown budget for tweaks after the first few trips.

Where the money goes component by component

Cost clarity comes from breaking the build into systems. Each category has a typical price band and an optional tier that can raise totals quickly.

Labor and shop rates

Professional hours bundle design, CAD, fabrication, wiring, plumbing, cabinetry, finishing, and testing. Expect 27k to 140k in labor at common market rates. Custom metal fabrication, CNC work, and DOT compliant seating or flooring require additional time. Complex electrical integrations with redundant charging and multiplex controls also add hours. Precision saves rework and protects resale value.

Electrical and power systems

Lithium battery bank: 200Ah to 600Ah installed, 3.5k to 15k depending on brand, BMS, and capacity.
Inverter charger: 2000W to 3000W units cost 1.2k to 3.5k installed, plus safety equipment and wiring.
Solar: 400W to 1200W panels, mounts, and controllers typically 1.5k to 4k installed.
DC to DC alternator charging: 500 to 1.8k installed depending on van platform and amperage.
Monitoring and distribution: breakers, busbars, fusing, and shunts add 400 to 1.5k.

Electrical is both a cost and an experience multiplier. Correct wire gauge, thermal protection, and clean routing prevent failures and make troubleshooting straightforward years later.

Comfort, water, and interior

Insulation and sound deadening: 600 to 2k for materials and installation, using closed cell foam, Thinsulate style products, and acoustic mat where appropriate.
Ventilation and AC: roof vent fans run 300 to 600 each plus install. High efficiency 12V AC units range 3.5k to 8.5k installed and demand larger battery capacity.
Heat: diesel or gas air heaters, 1.2k to 2.5k installed, including fuel tap and ducting.
Water: 10 to 40 gallon tanks, pump, accumulator, filtration, and PEX plumbing total 1k to 3k; add 500 to 1.5k for a compact water heater.
Shower and toilet: cassette or composting toilets run 700 to 1.6k. A composite shower pan with waterproof walls and gray water management can add 2k to 6k.
Windows and vents: 800 to 2.5k depending on number and tint. Each cut means trim, sealing, and time.
Cabinetry and furniture: 5k to 20k based on material choice, hardware, and whether you choose framed plywood, aluminum extrusion, or composite panels.
Seating and safety: swivel bases cost 600 to 1.5k installed. DOT rated smart floor and seating can add 5k to 12k and requires precise installation.

Exterior adds like roof racks, side ladders, awnings, bumpers, lighting, and suspension upgrades can tack on 2k to 15k. These are often the final touches that improve usability and stance while preserving payload.

Budget strategy, timeline, and hidden costs

Time affects money. A thorough custom build usually spans 6 to 16 weeks of shop time, depending on the queue and parts availability. Lead times for premium components such as 12V air conditioning, specialized windows, or seating systems can stretch schedules. Plan deposit timing around those long lead items so the install phase stays efficient.

Hidden costs to anticipate:
- Freight and crating for large components, sometimes 200 to 800 per shipment.
- Specialty tools and consumables if any site visits or add ons occur mid build.
- Weight management: every pound matters to payload and braking. Overbuilding cabinets or adding too many heavy accessories can force suspension upgrades and shorten tire life.
- Compliance: fuel taps, electrical protection, and seat anchoring must align with platform guidelines and best practices to keep insurance providers comfortable.
- Shakedown adjustments: after a few trips, budget 500 to 2k for tweaks to racks, shelves, or mounting points that reflect your real use habits.

Resale value rewards clean workmanship, serviceable wiring, and known brands in critical systems. A well documented electrical diagram, labeled circuits, and tidy plumbing are signals to future buyers and insurers. If you finance the van, remember that many lenders underwrite the vehicle, not the conversion, so your upfit spend is typically separate from the auto note. Some buyers choose platforms and options with stronger book values to support future trade scenarios.

When comparing quotes, align scope line by line and confirm inclusions down to wire gauge, fastener type, and finish materials. The lowest bid may omit critical safety or service items. The highest bid may include premium components you do not need. The right number matches how you travel, climate factors, and whether you need true four season performance.

Looking for next steps with a professional team in Fayetteville, Arkansas and beyond? Start by exploring build paths that match your travel style, capacity needs, and budget. See examples and plan your scope here:

OZK Customs designs and builds complete adventure vans and partial upfits with careful attention to electrical safety, weight balance, and long haul reliability. Our team guides you through scope definition, parts selection, and a clear schedule so your budget tracks to a finished rig that feels intuitive from day one.

Get a tailored estimate: Tell us your travel plans, passenger count, storage goals, and comfort must haves. We will translate that into a clean line item proposal with options that protect payload and resale. When you are ready, we handle the build and handoff at our shop so you can roll out confident.

Share your build goals and ideal timeline. We will map your budget to the right platform, components, and install plan, then deliver a custom van that works as hard as you do.