The 10 Most Important Van Build Mistakes to Avoid
When you scroll through Instagram, van life looks like a collection of sunsets, espresso machines, and perfectly made beds. But a photo doesn't capture the sound of a cabinet squeaking for 500 miles on a washboard road. It doesn't show you the moisture accumulating behind a wall panel or the frustration of a battery bank that dies the moment the sun goes down.
A Sprinter van is not a tiny home; it is a vehicle subjected to constant vibration, extreme temperature shifts, and dynamic loads. Treat it like a house, and it will fail. Treat it like an expedition tool, and it will last.
At Forged Vans, we have spent years refining our build process to solve the mechanical realities of life on the road. Whether you are looking to build your own or hire a professional, avoiding these ten common mistakes will save you money, time, and headaches down the road.
1. Using Static Materials in a Dynamic Environment
The most common mistake in the industry is building a van like a house. In a home, 2x4 lumber and wood screws are standard. But a house doesn't drive 70 mph down a dirt road.
The Problem: Wood expands and contracts with humidity. Over time, road vibration causes wood screws to back out and glue bonds to crack. This leads to the infamous "squeak and rattle" soundtrack that plagues many DIY and mass-market builds.
The Fix: We use 80/20 Aluminum Framing. It is bolted together with mechanical fasteners that are designed to handle dynamic loads. It doesn't warp, it doesn't rot, and once it is tightened, it stays tight. The result is a silent ride, no matter the terrain.
2. The "3-Season" Plumbing Setup
Many builders mount water tanks underneath the vehicle to save interior space. This works great in California in July. It works significantly worse in Colorado in January.
The Problem: An external, uninsulated tank is the first thing to freeze when temperatures drop. Even with heating pads, you are fighting a losing battle against wind chill at 60 mph.
The Fix: We place our water tanks inside the insulated envelope of the van, typically wheel-well shaped to maximize space. By combining this with eberspacher heaters, we ensure that if you are warm, your water is warm. This is the difference between a "camper" and a true 4-season expedition rig.
3. The "Black Box" Electrical System
Electricity is the lifeblood of a modern van. Too often, we see systems built with mismatched components, hidden fuses, and messy wiring nests buried behind permanent walls.
The Problem: If your electrical system is a "black box" that you don't understand, you are stranded the moment a fuse blows. Relying on cheap, proprietary components means you can't easily find replacements in remote towns.
The Fix: Component Transparency. We use Victron Energy components—the gold standard for marine and expedition reliability. We design accessible electrical cabinets so you can see exactly what is happening. We want you to know how your system works, not just hope that it does.
4. Ignoring the Payload Penalty
It is easy to overload a Sprinter. When you add heavy plywood cabinetry, ceramic tiles, and reclaimed wood ceilings, you eat up your payload capacity fast.
The Problem: A heavy van handles poorly. It is sluggish to accelerate, hard to brake, and sways in the wind. Furthermore, building near max capacity often forces you to spend thousands on aftermarket suspension upgrades just to drive safely.
The Fix: The 2,000 LB Advantage. By using aluminum composites and bamboo instead of heavy lumber, we save significant weight. This preserves your factory payload for what actually matters: your gear, your water, and your family.
5. Trapping Moisture (The Rust Trap)
Insulation is a hot topic. Many builds use spray foam or fiberglass. While these have high R-values, they can be dangerous in a metal van.
The Problem: Condensation is inevitable. When moisture gets behind spray foam, it gets trapped against the metal skin of the van. Over 3-4 years, this can rust your vehicle from the inside out.
The Fix: We use Havelock Wool. It is a natural, sustainable fiber that manages moisture. It absorbs humidity when it’s damp and releases it when it’s dry, preventing the condensation cycles that lead to rust and mold.
6. Reliance on the Alternator (False Off-Grid)
There is a misconception that if you have a battery, you are off-grid. But if that battery is small, or if you rely on the engine to charge it, you are tethered to the ignition.
The Problem: Many "weekender" builds rely on a DC-DC charger, meaning you have to drive the van for hours to recharge your batteries. If you want to park at a trailhead for three days to ski or climb, you’ll run out of power—or have to idle your engine like a generator.
The Fix: Solar Independence. We size our systems for stationary autonomy. With up to 600W+ of solar and massive 640Ah Lithium banks, our vans are designed to harvest enough energy from the sun to run induction cooktops and AC units without needing to turn the key.
7. The "Gear Tetris" Layout
It’s tempting to prioritize a massive fixed bed or a huge shower. But if you are a skier, cyclist, or climber, the gear has to go somewhere.
The Problem: Storing wet skis inside the living space or stacking bikes on top of the bed is a recipe for a miserable trip. We call this "Gear Tetris"—spending 20 minutes moving boxes just to make coffee.
The Fix: Purpose-Built Storage. We design dimensionalized "garages" specifically sized for crash pads, mountain bikes, and skis. We use L-Track systems that allow you to strap down heavy loads securely, keeping the living space clean and the gear space rugged.
8. Toxic Off-Gassing
In a small space like a van, air quality is critical. Standard RV construction often relies on cheap particle board, formaldehyde, and heavy chemical glues.
The Problem: When a van heats up in the sun or with a heater, these materials off-gas Volatile Organic Compounds (VOCs). You end up breathing in the glue that holds your van together.
The Fix: Materials That Matter. We prioritize sustainable, non-toxic materials like Bamboo, PaperStone, and Wool. It costs more than plywood, but it creates a living environment that is safe for you and your family.
9. The Permanent Layout Trap
Life changes. You might be a solo traveler today, a couple tomorrow, and a family of three next year.
The Problem: Most vans are built with fixed benches and permanent structures. If you need to haul a third passenger or a new piece of furniture, you can't.
The Fix: Flexibility. We use removable components, like our "Kid Crib" layout and DOT-approved removable seating. Add seats, remove seats, change storage, and keep your rig flexible for any adventure.
10. Underestimating the Cold
Insulation is only half the battle. If your heater isn't up to the task, or if your layout blocks airflow, you will still be cold.
The Problem: Standard propane furnaces often struggle at high altitudes and introduce moisture into the cabin (creating condensation issues).
The Fix: Hydronic Diesel Heating. We use systems like the Eberspacher (Espar) that tap into the vehicle’s fuel tank. They provide dry, consistent heat that is reliable at altitude, keeping the cabin comfortable whether you are in Baja or Banff.
The Forged Way
At Forged Vans, we don't just assemble parts; we engineer tools. We believe that the quality of your build directly impacts the quality of your adventure. By avoiding these common pitfalls and focusing on Function, Weight, and Reliability, we build rigs that are ready for the long haul.
We reject the assembly line in favor of hand-scribed craftsmanship. We reject cheap fillers in favor of sustainable materials. And we reject the idea that a van is just a vehicle—to us, it is the platform for your life’s greatest pursuits.
