Sprinter AWD Foundation Build-what does a great basic build look like for a family?

Korey
Jan 22
5 min read

Updated: 1 day ago

How We Built a Very Nice Family Campervan on a Budget

We found a 2023 low-mile AWD Sprinter 144" Crew Van at a fair price from a local solar business. It had a great service history and was in decent condition. These vans are tough to find at fair prices. Only 2023 and newer Sprinters with a 4cyl HO engine can use B20 Biodiesel. This is super important in California because most diesel gas stations only carry this fuel now. Older Sprinters can’t use it regularly. The 2023+ models can use both B20 biodiesel and regular low sulfur diesel, making them "future-proof" for fuel.

The van was in excellent mechanical shape and had regular service. However, it was used as a work truck for the solar company, so it needed some cosmetic refurbishing. We had some dents taken out (just door dents, no painting), refurbished or replaced some scratched interior panels, and got it back to looking really nice inside and out. The outside paint was in excellent condition and just needed some clay, ceramic, and buffing. A bit of work and money, but the savings were considerable compared to new—tens of thousands of dollars. This allowed us to keep the price under $100k. Try finding a used crew van that is 2023+ like this for cheap, not thrashed, with low miles, and still under factory warranty... it’s nearly impossible.

The Build Cost

This build cost about $41,000, including a new fridge, but not including refurbishing or replacing some interior panels and exterior cosmetic work. This cost included some must-haves and a lot of wants. We’ll walk you through the build item list. If you focus on must-haves, you can shave off almost $10k on the build cost.

What We’re Looking to Do

Before we started any of the build process, we got the smog done. We started with this 2023 AWD Crew van with OEM stock alloy wheels and only 17,000 miles! The factory warranty is good until 2026!

First things first, after we reconditioned the outside, we stripped down the entire interior, taking all of the panels, headliner, and eventually the floor out. The van was well taken care of, but we wanted it as close to new as possible. Little details like this ensure this van will be in tip-top shape.

Ventilation is Key

Then we added some rear vented windows. To keep costs down, we only did the rear quarters since the fan is in the front. Our goal is to keep this van below the $100k price point. Things add up quickly in a build. Ventilation is a must-have!

We painted the wheels by hand to save money. This makes it easy to touch up in the future and really helps transform the van. The van has OEM alloy wheels, so why change them? They look great, and this saves thousands.

We installed new Falken Wild Peak Tires, including a spare. They’re great tires with good mileage wear and are quiet. This really improves off-road and snow traction, but it’s a want, not a must-have.

Insulation and Sound Deadening

We won’t go into great detail, but when the van is apart, we begin insulation and sound deadening. We used only top materials: Dynamat Extreme (which has no tar in it like most do) and 3M Thinsulate. We not only do the walls, but we also do the doors. We begin all the interior wiring during this stage.

When we had the door panels off, we upgraded the front speakers with an adapter kit from DIY van. We put "DS" Kicker 6 1/2 inch speakers in this van as they sound a bit better with the stock radio. We also plan to wire in rear speakers. This helps with the sound, and adding an amplifier and sub makes a big difference.

The Interior Layout

Moving forward, we installed a Roost Vans lower wall brace kit for the bed and the front. This allows us to mount not only the bed but other items as well. With this wall kit, we had to make new panels since the front stock in this van wouldn’t work, and the panels had been beaten up a bit from transporting work materials.

The magic of the internet and many hours later, the upholstered panels are in, and we’re moving forward with wiring. LED lights are now installed, and the fan trim ring is in place. The L track is also installed for the cabinets. This was a lot of work up to this point.

Storage Solutions

You can never have enough storage, right? We installed Van Essentials semi-rigid removable cabinets. They offer an insane amount of storage, and if you bump into them, they won’t hurt your head like solid cabinets would.

In this van, we’re going to do a "basic" floor insulation. This makes a pretty good difference as well. We layered it with closed-cell foam from Soundskin. To keep costs way down, we used cork insulation for the rear of the van on the floor instead of Dynamat and foam. This saves almost $700 in materials and still provides decent insulation and sound absorption.

The Floor

We used interwoven Compass Luna Metro flooring, which is now cut and ready for install. Special glue is used, and careful cutting of the material is needed. The floor material alone is around $900.

We modified the floor and installed longer rails so two bench seats can fit inside the van, accommodating up to 8 people, even with the bed with one panel flipped up!

The Bed

The Roost Vans Flip Up bed is a game changer. The rear and front panels flip up to make a couch or give you better access to gear. They are height adjustable up to 36" (to clear a mountain bike) and are removable by loosening four bolts on each panel. A custom mattress is also in the van, specifically designed to use with the flip-up panels!

Dining Area

We added a Lagun table and extended tracks with swivel seats, making a perfect dining area without moving any gear. This is a must-have but can easily be done later or DIY.

Future Modifications

We’ve thought about future modifications and prepared the van to easily modify. Other mods that can be done in the future include a modular self-contained sink and a diesel heater. We set the van up for these mods and more as needs might expand. The van includes a new removable chest fridge freezer.

Pop Top - GAME CHANGER

Adding a Pop top on this van is a game changer for families 4+ transforming the van to not only easily sleep everyone, but allowing for ALL of the gear to fit inside the van and not move anything to go to sleep, dress, or grab food/gear. This however can significantly increase the budget by $15-25k easily.

Conclusion

Building a campervan on a budget is totally doable! With a bit of creativity and hard work, you can create a comfortable, functional space for your family adventures. Whether you’re hitting the road for a weekend getaway or a longer journey, having a campervan can make all the difference.

So, are you ready to hit the road?