The Premier Custom Camper Van Builder in Colorado
HANDCRAFTED IN LONGMONT, COLORADO
Vans for a life lived deliberately. Lightweight, 4-season Sprinter conversions engineered to conquer high-altitude passes, sub-zero winters, and everything the Rockies throw at you.
Why Building a Van for Colorado
Is Fundamentally Different
ENGINEERED FOR ALTITUDE
A conversion that works in Southern California will fail in the Rockies. Colorado's combination of extreme elevation, brutal winters, and corrosive road treatments demands purpose-built engineering from the frame up.
01
The I-70 Weight Problem
Hauling a heavy, wood-framed conversion up the Eisenhower Tunnel or over Vail Pass destroys transmissions and overheats brakes. Every pound matters at 11,000 feet where your engine is already down 30% on power. Our 80/20 extruded aluminum framing and aerospace-grade composites cut up to 2,000 lbs from the build, preserving your Sprinter's payload and braking capacity for steep, sustained descents.
UP TO 2,000 LBS LIGHTER
02
The Winter Reality
A generic "4-season" label from a coastal builder doesn't cut it in Steamboat in January. We engineer our vans with dual-circuit hydronic heating that simultaneously pre-heats your engine block and your cabin. Paired with R-3.6 Havelock Wool insulation that won't crack, compress, or squeak when frozen, our vans stay warm when it actually matters.
TESTED FOR WINTER TEMPS
03
Magnesium Chloride & Rust
Colorado's de-icing agent of choice is one of the most corrosive substances your vehicle will encounter. It attacks wiring, hardware, and unsealed penetrations relentlessly. We use marine-grade, corrosion-resistant fasteners and seal every exterior penetration point — because we refuse to build something that the Front Range will eat alive in five years.
Marine-Grade Hardware
Every Forged Van is a custom commission — handcrafted for how you actually use it in Colorado and beyond. Don't see your layout? We'll build it.
Custom Sprinter Conversions
for the Mountain West
Forged for Your Pursuit
| Feature | Forged Vans | Production Class B |
|---|---|---|
| Price Range | $155k – $210k+ | $180k – $260k+ |
| Framing | 80/20 Extruded Aluminum | Plywood / Particle Board |
| Heating | Diesel Hydronic Heater | Electric Heat or None |
| Power System | LiFePO4 Lithium (up to 920Ah) | Lead-Acid / Entry Lithium |
| Materials | Bamboo, Richlite, Havelock Wool | Particle Board, Fiberglass |
| Layout | ✓ Fully Custom to You | 2–3 floor plan options |
| Winter Plumbing | ✓ Internal Tanks + Routing | Exterior-exposed lines common |
| Colorado Engineering | ✓ Built for Altitude & Cold | Generic "4-Season" label |
| VOC-Free Interior | ✓ Non-Toxic Materials | Solvent-heavy glues standard |
| Transparency | ✓ Visit Our Longmont Shop | Ships from factory |
A Forged Van costs about the same as a factory Class B, but you get a van designed for your life, not a one-size-fits-all assembly line product.
Custom Forged vs. Production Class B
The Investment
We don't run a faceless assembly line. When you commission a Forged Van, you're invited into the process from day one — from initial design to the first night in your finished rig.
Built in Colorado. Tested in the Wild.
Your Build, Start to Finish
01
Discovery Call
We learn how you live — ski seasons, remote work, family travel — and match you to the right platform and layout.
02
Design
Discuss your layout, design elements, features, and add-ons to finalize your own custom Forged Van rig.
03
The Build
14–20 weeks of focused craftsmanship. Photo updates and open-door shop visits keep you connected.
04
Delivery
Full systems walkthrough, a day of hands-on training, and a test run, so you drive away confident in every system.
Colorado Builds. Colorado Tested.
from the shop to the wild
BOULDER, CO - FAMILY BUILD
THE MORGAN FAMILY EL CAP
A 170 AWD conversion for a family of five who needed seating and sleeping for two adults and three kids, and genuine off-grid capacity for days to weeks at a time. Designed for camping, mountain biking, skiing, and more. Built with 920 Ah battery, 900W of solar, bamboo cabinetry and countertop, King/Queen bunk, & gear drawer.
“We absolutely love everything about our van. It’s a special place for core memories and adventures across the Rockies in all seasons.”
We’re out in the van any chance we can get, skiing at our favorite Colorado resorts, camping across Colorado, Utah, and Wyoming, and finding any excuse for a fun, family adventure.”
— THE MORGAN FAMILY, BOULDER
Lake Tahoe, CA - FAMILY BUILD
THE Rich FAMILY Denali
A 144 AWD conversion for a family that needed a van built for the way they actually live. Enough room for gear storage, sleeping, but also a comfortable, communal space for road trips and weekend hangouts. built with a spacious hanout area, modular sleeping setup, adventure-ready storage, battery storage, & solar.
“This van isn’t just about having a cool setup—it’s about access. Access to more time outdoors, more road trips with family, and more opportunities to live life to the fullest.
I hope to drive this thing for a decade or two. And if the past few months have been any indication, it’s already proving to be exactly what we needed.”
— The Rich Family, South Lake Tahoe
Common questions
Frequently Asked Questions
About Colorado Van Builds
-
For most Colorado driving — including I-70 winter commutes and forest service roads — the factory AWD Sprinter paired with quality snow tires outperforms aftermarket 4x4 conversions. AWD is lighter, preserves your warranty, and handles predictably on icy passes. We recommend true 4x4 only for clients who need low-range gearing for extreme off-road access, like unmaintained mining roads above treeline. For your typical ski town commute or national forest campsite, AWD is the superior choice.
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Every Forged Van uses internally routed plumbing. No exterior-exposed lines, period. All our water tanks are enclosed within the insulated cabin envelope over the wheel well. All freshwater lines run through heated zones. If you have your cabin in a comfortable warm temp, you’re water will work.
As with any equipment, conditions may change where it’s still recommended to run your van ‘dry’. If you’ll be in extreme temps and away from the van, it’s always best to play ti safe and protect your equipment.
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A full Forged Van conversion ranges from $155,000 to $210,000+ depending on layout, electrical capacity, and options. For context, a comparable production Class B like the Winnebago Revel starts around $185,000 with far less customization and lower-grade components. Our builds use aerospace-grade aluminum framing, Victron lithium power systems, and sustainable materials like solid bamboo and Richlite — materials that justify the investment through decades of durability.
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With over 300 days of sun a year, Colorado is built for Solar powered adventured. Throughout the summer, your van should constantly charge during the day, with draw at night for equipment & AC.
During the winter, snow cover can knock your panels offline for days. But a simple brush off and good power management should keep your van powered consistently.
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We don't build units — we build craft. Our 80/20 extruded aluminum framing saves up to 2,000 pounds compared to wood-framed builds. Our dual-circuit hydronic heating is engineered for sustained sub-zero operation, not just rated for it. We use non-toxic, sustainable materials like bamboo and Havelock Wool instead of particle board and fiberglass. And every build is a custom commission — visit our Longmont shop anytime during the process.
There’s a reason why athletes like Alex Honnold and Emily Harrington, plus families across the Front Range choose Forged.
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A typical Forged Van build takes 14 to 20 weeks from sign-off to delivery, but it often depends on current availability and complexity.
We don't rush builds and make sure each one is built to the Forged Standard. You’ll have regular photo and video updates so you can watch your van come together week by week.
YOUR ADVENTURE STARTS HERE
READY TO BUILD YOUR COLORADO VAN?
Apply for the build slot, meet the team, and start designing the van that matches the life you want to live.
Forged Vans is Colorado's trusted custom Sprinter conversion company. While we build for clients nationwide, we are the local choice for adventurers across the state.
PROUDLY SERVING THE FRONT RANGE & BEYOND
DENVER
BOULDER
LONGMONT
FORT COLLINS
COLORADO SPRINGS
GOLDEN
DURANGO
TELLURIDE
BRECKINRIDGE
VAIL
CRESTED BUTTE
ASPEN
STEAMBOAT SPRINGS