Sprinter AWD Foundation Build

Korey
Jul 31
6 min read

Updated: 6 days ago

This van is completed and ready for new owners!

We found a 2023 low mile AWD Sprinter 144" Crew Van at a fair price from a local solar business for sale that had a great service history and was in decent condition. These are very difficult to find at a fair prices. Only 2023 and newer Sprinters with a 4cyl HO engine can use B20 Biodiesel. This is very important living in California because almost all of the diesel gas stations only carry this fuel now and the older Sprinters cannot use this on a regular basis. The 2023+ Sprinters can use both B20 biodiesel and regular low sulfur diesel so they are "future proof" for fuel.

The van was in excellent mechanical shape and had regular service, but was used as a work truck for this solar company so it needed a bit refurbishing on the cosmetic end, it was a work truck, its a big reason we got a fair price on it. We had some dents taken out, refurbished some interior panels, replaced a few plastic panels due to scratches, and was able to get it back to looking really nice inside and out. The outside paint itself was in excellent condition. A bit of work and $ but the savings was considerable compared to new...tens of thousands of dollars.

This build is about $41,000 with a new fridge not including refurbishing/replacing some interior panels and exterior cosmetic work (taking out small dents and scratches, normal wear and tear, especially because it was used as a work van). Even buying a used van, this would be very difficult to do for what we are selling the van for, try finding a "Crew Trim" AWD with this many miles with the new 4 cyl HO engine for anywhere around $60k...nearly impossible.

Van Completed (Tour Steps are now added on, but not shown)

Before we started any of the build process. Getting Smog done ...staring with 2023 AWD Crew van with OEM stock alloy wheels with only 17,000 Miles! Factory warranty good till 2026!

First things first after we recondition the outside taking a few small dents we strip down the entire interior taking all of the panels, headliner, and eventually floor out.

Then we add some rear vented windows, to keep costs down we did only the rear quarters since the fan is in the front. Goal is to keep this van below the $100k price point, things ad up very quickly in a build.

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

New Falken Wild Peak Tires INCLUDING spare, great tire, very good mileage wear as well and quiet

Painted the wheels, some wheel paint really made the wheels look much better

Already making the van look a million times better. Will be adding some Aluminess Touring steps soon to make it very easy to get in, they are BO for the moment.

Installed a Max Air fan with remote and 250w of solar on the factory rails as well. We do this before beginning the interior and this needs to be done when the headliner is out.

LETS MAKE IT QUIET, I HATE A LOUD VAN

We won't go into great detail, but when the van is apart we begin insulation and sound deadening. We have an entire blog on this. We used only top materials, Dynamat Extreme that has NO TAR in it like most do and 3M Thinsulate. We not only do the walls, but we do the doors as well. We begin all the interior wiring as well during this stage. In this photo you see beginning of this stage, take notice how much material we use...not just a few patches. This really makes a huge difference! In this photos the window had not been cut in yet.

Rear doors Completed

Front doors before; just showing detail of what we do that makes our vans so quiet, This is example of another build...we did the same thing in this build.

We use more material in one door than most do in two...it makes a very big difference! Dynamat the doors and insulate them as well , before panel goes back. This is a step many skip in their builds or do only half of what we do.

front door inner panel insulation, we also upgradedd teh speakers at this time as well

When we had the door panels off, upgraded the front speakers with an adapter kit from DIY van...stock vs aftermarket. We put "DS" Kicker 6 1/2 inch. in this van as they sound a bit better with stock radio vs CS thats shown, but you can see the difference in size and quality its signficant. We also will wire in rear speakers as well. This helps with the sound, adding an amplifier and sub makes a very big difference. The stock head unit power is pretty bad, so you only get about a 25% improvement over stock even when adding rear speakers.

Size comparison vs stock. Stock on left/upgrade size on right

Adding rear speakers is a bit of work, you have to take dash apart, get special pins so you can add rear lines, take the harness out and then run the wires directly to the outputs and run wires to rear doors. All factory correct when done, however you will need to take the van to a dealer if you want to add rear fader control. This is how you correctly do this, no splicing any wires in...that is a sloppy shortcut that doesn't allow you to add an amplifier later correctly.

rear speakers on door. In this van we used Kicker 6 1/2 DC dual coaxial speakers both front and back

Moving way forward, We are installing a Roost Vans lower wall brace kit for the bed as well as in the front so you can mount not only bed but other items. Also with this wall kit you have to make new panels as the front stock in this van will not work and the panels had been beaten up a bit from transporting work materials.

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

You can see here the solar controller is installed as well as the DC outlets (12v) in the walls are done. These are to run fridges and things like a bike pump or other 12v low power accesories. We have yet to tackle the floor that will be in the next step.

L track for cabinets and LED lighting. The L track is a bit of work to install, you can't just put it in, you need a support structure to hold it

Van Essentials semi rigid REMOVABLE cabinets. These have an insane amount of storage and if you bump into them they unlike a solid cabinet don't hurt your head

You never have enough storage no matter what right?

Floor insulation

In this van going to do a "basic" floor insulation, this makes a pretty good difference as well. Here is the front...Dynamat layer, see its everywhere.

Now we layer with closed cell foam from Soundskin

An here you see it layed down, even over the battery hatch on the drivers side

To keep costs WAY down we will use cork insulation for rear of van on floor and not drop Dynamat and foam. This saves almost $700 in materials and still provides decent insulation and sound absorbtion. This is our level 1 floor package; the front done like above and rear like this. It also allows if you upgrade to a Smart floor...easy install, you don't have to remove Dynamat...that is super difficult.

Two layers.

Interwoven Compass Luna Metro flooring 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 for this floor.

Installed

trimming and hardware now installed with extended dual seat rails. (for two rows of seats)

Floor modified and longer rails installed so two bench seats can be put inside of the van to fit up to 8 people, even with the bed with one panel flipped up!

Roost Vans Flip Up bed...rear and front panels flip up to make a couch or give you better access to get to gear. They are height adjustable up to 36" (clear a mt bike) and are removable by loosening 4 bolts on each panel. Super nice beds. A custom mattress is also in the van specifically designed to use with the flip up panels!

Large queen size bed