Cargo Vans

Cargo vans are the most popular choice for van conversions, and for good reason. They offer standing height, enough space to build a comfortable living area, and they're still small enough to drive and park like a normal vehicle. But not all cargo vans are created equal.

Why cargo vans dominate the van life scene

When most people think "van life," they're picturing a cargo van conversion. And there's a reason for that - cargo vans hit a sweet spot that's hard to beat:

  • Standing height - High-roof models let you stand up inside, which makes a huge difference for livability
  • Drivability - They drive like a large SUV, fit in normal parking spots, and don't need special licenses
  • Stealth - A white cargo van doesn't scream "I'm living in here" the way a school bus or RV does
  • Parts and service - These are commercial vehicles with dealer networks everywhere
  • Resale - Well-built van conversions hold their value reasonably well

The main downside is cost. A decent used cargo van will run you $15,000-40,000 depending on year, mileage, and model - and that's before you build anything. New ones are $35,000-55,000+. This is the most expensive base vehicle option by far.

Mercedes Sprinter

The Sprinter is the "default" van for conversions and the one you see most on Instagram. It's a great van, but it's also the most expensive option and comes with some real downsides that people don't always talk about.

✓ Pros

  • Available in multiple lengths (144" and 170" wheelbase) and heights
  • Excellent build quality and driving experience
  • Good fuel economy for its size (diesel models get 18-22 mpg highway)
  • Massive aftermarket support - tons of accessories, parts, and build guides available
  • Strong community - easy to find help and inspiration
  • Available in 4x4 (factory AWD on newer models)

✗ Cons

  • Expensive - Most expensive van to buy. Used ones with reasonable miles are $25k-45k. New is $45k-60k+
  • Expensive to repair - Mercedes parts and labor costs are no joke. A simple repair can be $1,000+ that would be $300 on a domestic van
  • Diesel models require DEF fluid and have emissions systems that can be problematic and expensive to fix
  • Pre-2019 models had a reputation for rust, especially around the roof and seams
  • Finding a good independent mechanic can be harder in rural areas

My honest take: The Sprinter is a great van, but it's overhyped for DIY builders. The premium you pay for the Mercedes badge doesn't always translate to a better van life experience. If you can get a good deal on one, go for it - but don't stretch your budget just because it's the "cool" choice. That money is better spent on your build.

Ford Transit

The Transit has become increasingly popular in the van build community, and I think it's the best overall value for most people. It's cheaper than a Sprinter, easier and cheaper to maintain, and the build quality has gotten consistently better since its US introduction in 2015.

✓ Pros

  • Significantly cheaper than Sprinter - both to buy and maintain
  • Gas engine option (3.5L EcoBoost) - no DEF, no diesel emissions headaches
  • Ford dealers and mechanics are literally everywhere
  • Parts are cheap and readily available
  • Available in multiple lengths and roof heights
  • AWD available on newer models
  • Widest interior of the big three vans

✗ Cons

  • Gas models get worse fuel economy (14-18 mpg) compared to diesel Sprinters
  • Interior walls are more curved than Sprinter, which can complicate builds slightly
  • Smaller aftermarket than Sprinter (though growing fast)
  • Some early model years had transmission issues - 2018+ are better
  • Ride quality isn't quite as refined as Sprinter

Why I lean toward the Transit: When you factor in purchase price, maintenance costs, and parts availability, the Transit often saves you $10,000-20,000 over a comparable Sprinter over the life of ownership. That's money you can put into your build, or into the experiences you're building the van for in the first place.

Ram ProMaster

The ProMaster is the underdog of the van conversion world. It has some unique advantages that make it worth serious consideration, but also some quirks you should know about.

✓ Pros

  • Front-wheel drive - flat cargo floor with no driveshaft hump, which simplifies builds enormously
  • Widest interior of any van in its class - almost a foot wider than a Sprinter
  • Lowest floor height - easier to get in and out, more interior height per exterior inch
  • Generally the cheapest of the big three to buy
  • Tight turning radius thanks to FWD

✗ Cons

  • No AWD/4WD option - if you need off-road capability, this isn't your van
  • FWD means worse traction on hills and in snow/mud compared to RWD or AWD vans
  • Driving experience isn't as polished - can feel a bit more "trucky"
  • Smaller aftermarket community and fewer conversion-specific products
  • Some complaints about build quality and reliability compared to Transit/Sprinter

The ProMaster is an excellent choice if you prioritize interior space and don't need AWD. That flat floor is genuinely great for building - no working around a driveshaft hump, no uneven surfaces. If you're on a tighter budget and mainly plan to stick to paved roads and established campgrounds, it's hard to beat the ProMaster on value.

Chevy Express / GMC Savana

These are the "old school" vans that have been around forever. They're not as glamorous as the European-style vans above, but they have some compelling advantages, especially on a budget.

✓ Pros

  • Cheap - can find good ones for $8,000-15,000
  • Bulletproof reliability - the 6.0L V8 is nearly indestructible and dead simple to work on
  • Cheapest parts and maintenance of any van
  • Any mechanic anywhere can work on it
  • Very strong aftermarket for lifted/off-road builds
  • Available in extended length

✗ Cons

  • No factory high roof - standard roof means no standing height. Aftermarket high-top conversions exist but are expensive ($5,000-10,000+)
  • Terrible fuel economy - the V8 gets 12-15 mpg
  • Feels dated compared to the European vans
  • Narrower interior than the big three
  • Worse crash safety ratings and driving dynamics

If your budget for the base vehicle is under $15,000 and you can live without standing height (or you're willing to invest in a high-top later), the Express/Savana is probably the most cost-effective option. The reliability and cheap maintenance alone can save you thousands over the life of the van.

Minivans and small vans

Don't overlook minivans. Seriously. If you're doing weekend trips, solo travel, or just want something simple and affordable, a minivan conversion can be incredibly practical.

Why minivans deserve consideration:

  • Cost - A good used minivan is $5,000-15,000. That's potentially $30,000+ less than a Sprinter
  • Fuel economy - 20-28 mpg vs. 14-18 for full-size vans
  • Easy to drive and park - fits in any parking spot, any garage
  • Simpler builds - a basic minivan camper setup can be done in a weekend
  • Lower insurance - insured as a regular passenger vehicle
  • Ultimate stealth - nobody thinks twice about a minivan parked anywhere

Popular minivan choices include the Honda Odyssey, Toyota Sienna (the hybrid AWD version is incredible for this), Dodge Grand Caravan, and Chrysler Pacifica. The Sienna Hybrid with its AWD system and 35+ mpg is honestly one of the most practical camping vehicles you can buy.

The tradeoff is obvious - you can't stand up, you have less space, and you're limited in what you can build. But if you're honest about your needs, many people would be better served by a $10,000 minivan setup than a $50,000 Sprinter build.

Buying tips for cargo vans

Where to look

  • Commercial fleet auctions - Companies sell off their vans at 150k-200k miles. These are often well-maintained (regular oil changes, documented service history) and significantly cheaper than private sales
  • Government surplus auctions - Similar deal, often lower miles
  • Facebook Marketplace and Craigslist - Private sales can be great deals or terrible - do your homework
  • Dealer inventory - Most reliable but most expensive. Good for new or certified pre-owned

What to look for

  • Rust - Check wheel wells, rocker panels, roof seams, and around the windshield. Surface rust is fine, structural rust is a deal-breaker
  • Maintenance records - Regular oil changes and service matter more than low miles
  • Transmission condition - Vans are heavy and transmissions are expensive to replace. Get it inspected
  • Roof condition - You'll be cutting holes in it and standing on it. Check for dents, rust, and previous repairs
  • Get a pre-purchase inspection - $100-200 at a mechanic is cheap insurance against a $5,000 surprise

Don't be afraid of high miles. A well-maintained diesel Sprinter with 200,000 miles can easily go another 200,000. A neglected one with 80,000 miles might be a money pit. Maintenance history matters far more than odometer reading.

My recommendation

Best overall value: Ford Transit with the 3.5L EcoBoost gas engine, high roof, 148" wheelbase. You get standing height, enough space for a full build, reasonable fuel economy, and maintenance costs that won't ruin you. Used 2018+ models with under 100k miles typically run $20,000-30,000.

Best on a budget: Chevy Express or GMC Savana. If you can deal with no standing height (or budget for a high-top later), these are the most reliable and cheapest to own. Great for minimalist builds or builds where you spend most time outside.

Best for space-conscious builds: Ram ProMaster. That flat floor and extra width give you building options the others can't match. Just make sure you don't need AWD.

If money is no object: A 2022+ Sprinter 170" with the 4-cylinder diesel and factory AWD is a fantastic van. Just go in with your eyes open about maintenance costs.