VAN LIFE GLOSSARY: 50+ Terms Every Van Owner Should know

Feb 8

Most newcomers to the world of van conversions get overwhelmed by the jargon. You start looking for a "camper" and suddenly you’re hit with a barrage of terms like "Ah," "Shore Power," and "Payload."

At Forged Vans, we don't build RVs; we build expedition tools. To use a tool correctly, you need to understand the technical manual. This glossary is designed to bridge the gap between "Van Life" aesthetics and the actual engineering required to live and explore on the road.

I. CHASSIS & DIMENSIONS

Before the cabinetry and the lithium batteries, there is the chassis. In our world, that almost exclusively means the Mercedes-Benz Sprinter.

144" Wheelbase: The distance between the front and rear axles. This is the "standard" Sprinter length, known for its agility. It serves as the foundation for The Basecamp and The Dreamcatcher.
170" Wheelbase: The long-wheelbase version of the Sprinter. It offers significantly more interior volume for families or professional athletes who need long-term liveability, such as in The El Cap & The Denali
AWD (All-Wheel Drive): The modern Sprinter drivetrain that replaced the older 4x4 system. It automatically distributes torque to provide traction on snow and dirt without manual engagement.
Payload Capacity: The maximum weight a vehicle can carry, including the build, gear, fuel, and passengers. This is why weight reduction is a core philosophy at Forged—it preserves suspension and handling.
High Roof: The standard roof height for professional conversions that allows an adult to stand upright inside the van.
GVWR (Gross Vehicle Weight Rating): The maximum total safe weight of your vehicle, set by the manufacturer.
Curb Weight: The weight of the van with a full tank of fuel but no passengers or gear.

II. STRUCTURAL ENGINEERING & EXTERIOR

How a van is put together determines if it will last a decade or fall apart after one season of washboard roads.

80/20 Aluminum: A modular framing system made of T-slotted aluminum extrusions. We use this instead of wood to save weight and ensure the structure never warps or rots.
Hand-Scribing: The process of manually fitting a cabinet or panel to the complex curves of the van’s steel walls. This eliminates gaps and prevents rattles.
Mechanical Fasteners: Using bolts, Plusnuts, and Rivnuts to secure the build to the chassis rather than glue and staples.
L-Track: Also known as "Airliner Track." A high-strength rail system recessed into floors or walls for modular gear storage.
Flare/Body Capsule: Extensions installed on the rear side panels of the van that allow you to sleep sideways, saving interior floor space.
Roof Rack: An aluminum framework used to mount solar panels, decking, and recovery gear.

III. THE ELECTRICAL GRID

Modern van life relies on power. Understanding these terms is the difference between a working fridge and a dead battery in the middle of nowhere.

LiFePO4 (Lithium Iron Phosphate): The gold standard for van batteries. They are lighter, safer, and last longer than traditional batteries.
Amp Hour (Ah): A measure of battery capacity. Think of it like the size of your "fuel tank." A 640Ah bank is a massive "tank" for off-grid use.
Inverter/Charger: A device that converts DC power from your batteries into AC power (110V) for laptops or espresso machines.
Shore Power: An external power connection used to charge your batteries or run appliances from a house or campground.
Solar Array: The collection of solar panels on the roof measured in Watts. 900W is a high-output array for total independence.
DC-DC Charger: A system that charges your house batteries using the van's alternator while you are driving.
Solar Controller (MPPT): A device (often from Victron Energy) that optimizes the energy coming from your solar panels to charge your batteries efficiently.
Battery Monitor: A digital interface that tells you exactly how much power you have left.

IV. THERMAL CONTROL & NON-TOXIC LIVING

Van life is a 4-season pursuit. If your rig isn't insulated and heated correctly, it's just a metal tent.

Hydronic Heating: A premium system that circulates heated fluid to provide both cabin heat and instant hot water.
R-Value: The measure of a material's resistance to heat flow.
Thermal Bridging: The process where heat or cold transfers through the metal ribs of the van.
Havelock Wool: Sustainable, non-toxic insulation made from sheep's wool that manages moisture and resists mold.
3M Thinsulate: A hydrophobic (water-repelling) synthetic insulation often combined with wool for superior performance.
VOCs (Volatile Organic Compounds): Harmful chemicals that "off-gas" from cheap boards. We use non-toxic materials like Bamboo and PaperStone to avoid this.
Sound Deadening: Butyl mats, like Kilmat, applied to the van's metal skin to reduce road noise and vibration.
Extractor Fan: A roof-mounted fan, like a Maxxair, used to pull moisture and cooking smells out of the van.

V. WATER & PLUMBING

Potable Water: Fresh water that is safe for drinking and cooking, stored in an insulated tank.
Grey Water: Used water from your sink or shower stored in a separate waste tank.
Accumulator Tank: A small pressure tank that evens out the flow of water and reduces pump cycling for a quieter system.
Instant Hot Water: A system that provides hot water on demand for showers or dishes.
Outside Shower/Rinse Station: A rear-mounted port used for cleaning gear or showering outdoors.

VI. FURNITURE & LIVEABILITY

Galley: The van’s kitchen area.
Murphy Bed: A bed that folds up against the wall to reveal a "hangout zone" or workspace during the day.
Lagun Table: A highly adjustable, swiveling table mount used for dining or as a standing desk.
PaperStone/Richlite: Extremely durable, sustainable countertop materials made from recycled paper and non-toxic resin.
Kid Crib: A specialized, removable drawer or bunk system designed for safe family travel.
Cassette Toilet: A portable toilet with a removable waste tank for easy disposal in standard restrooms.
Composting Toilet: A portable toilet meant to collect and compost waste.
Lounge Bench: Multi-use seating that often converts into a secondary sleeping area or workstation.

VII. ADVANCED OVERLANDING & EXPEDITION GEAR

For those venturing 40 miles past the pavement, standard van features aren't enough. Advanced gear ensures you can get in—and out—safely.

Recovery Boards: High-traction plastic planks (like MaxTrax) used to get a van unstuck from sand, mud, or snow.
Winch: A motorized pulling device mounted to the front bumper for self-recovery or assisting other vehicles.
Snorkel: An elevated air intake that allows the engine to breathe cleaner air in dusty environments and protects against water ingestion during shallow crossings.
On-Board Air: A built-in compressor used to "air down" tires for better traction on soft dirt and "air up" once you return to the highway.
Rock Sliders: Heavy-duty steel rails mounted to the chassis to protect the van's rocker panels from rocks and stumps.
Skid Plates: Protective metal plates installed under the van to shield the engine, transmission, and fuel tank from impact.
All-Terrain Tires (AT): Tires with aggressive tread patterns designed for both highway comfort and off-road grip (e.g., BFGoodrich KO2).
Auxiliary Fuel Tank: An additional or oversized tank that extends the van's range for long-distance desert or mountain travel.

Jonathan Morgan