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
Price Range
Forged
$155k – $210k+
Production
$180k – $260k+
Framing
Forged
80/20 Extruded Aluminum
Production
Plywood / Particle Board
Heating
Forged
Dual-Circuit Hydronic
Production
Single Furnace
Power System
Forged
Victron Lithium (up to 640Ah)
Production
Lead-Acid / Entry Lithium
Materials
Forged
Bamboo, Richlite, Havelock Wool
Production
Particle Board, Fiberglass
Layout
Forged
Fully Custom to You
Production
2–3 floor plan options
Winter Plumbing
Forged
Heated Tanks + Internal Routing
Production
Exterior-exposed lines common
Colorado Engineering
Forged
Built for Altitude & Cold
Production
Generic "4-Season" label
VOC-Free Interior
Forged
Non-Toxic Materials
Production
Solvent-heavy glues standard
Transparency
Forged
Visit Our Longmont Shop
Production
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.

  • 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.

  • 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.

  • 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.

  • 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.

  • 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