Since moving to Colorado in 2024, Rachael and I have noticed that we are using our travel trailer less and less. We find ourselves more on the move and dreading connecting to and towing our Casita. While we LOVE the trailer and it has served us well, it has been on our land for months. We have felt drawn back to a van for a while now and finally made it happen. We picked up a 2013 E250 Extended Cargo Van for a steal and are super excited to get to work making it into a comfortable camper van.

The Van
The van is extremely simple, just the way we like our vehicles. The E250 Extended Cargo Van is outfitted with manual locks, manual windows, and vinyl flooring. The AC and heater work and the van’s only issues are cosmetic. The van was used as a plumbing van and the exterior shows some dings and dents. The chassis has zero rust and the van needs nothing to be road-worthy.

The van is powered by a 5.4L V8 engine with plenty of power to carry us and our gear on adventures. The fuel mileage appears to be about the same as our Lexus GX470 and there were millions of 5.4L Fords built around the world, so parts and service are easy to arrange around North America.






The van will need a new set of tires soon but is otherwise in great shape and has even made a trip back to Oklahoma for the holidays with no problems.
The Plan


We have broken down the build plan into 4 phases to coincide with our travel plans and the funds we have available for the van.
Phase 1: Maintenance and Minimum Camping Setup
Completion Goal: April 2025
The first phase of the build revolves around establishing a maintenance baseline and a minimalist camping setup. Rachael and I have a few trips planned for April 2025 and Rachael’s summer season begins in May at Overland Expo West. The goal is to have the van insulated, a bed platform built, and a simple battery and inverter setup installed.
Phase 2: Winter is Coming
Completion Goal: November 2025
We plan to work out the kinks of travel in the van during the summer and build the interior accordingly. Phase two will include preparing the van for ski season and winter camping in Colorado and New Mexico.
- Diesel Heater
- Bigger Lithium Battery Bank
- 32″ Light Bar in Grill
- NoCo 10a Shore Charger
Phase 3: Raise the Roof
Because I am 6’3” tall and want to be able to stand up inside the van, this build will require a high-top roof or pop top. A fiberglass roof might work, but we have eventual plans to travel internationally and that will require the van to fit in a shipping container. A pop top has quickly become the most obvious solution. We plan to either pay an outfitter to install a pop-top roof or we will DIY a pop-top of our own. Time and finances will tell.

There are a fair number of roof outfitters such as Colorado Campervans, FieldVan/Sportsmobile, etc. The cost for these pop tops is typically around $14,000 or more and there does not appear to be a consensus on the quality of the installation from any of the companies. A DIY solution is obviously more time consuming but is also a fraction of the price. The most appealing plan so far is to attach a roof top tent to the roof, cut a hole in the roof and the bottom of the tent, and enjoy the extra head space.

Phase 4: Off-Road Upgrades
The E250 is essentially a full-size Ford truck chassis, so it is mostly capable of the forest roads that we like to camp on. We tend to get into situations and areas that require 4×4 or an extensive recovery system at the bare minimum to ensure our 8000-plus pound van stays the course.
The ideal situation will include a 4×4 swap, but like the pop top, a 4×4 conversion is costly. In the absence of a 4×4 conversion, we will likely opt for a much cheaper solution including off-the-shelf lift components and larger all-terrain tires. The plan is to install the Weldtec Ocotillo 3” Suspension Lift and run 32-33” tires. The increased articulation and ride quality will be welcome and the extra sidewall of a 32” tire is always preferred for airing down and off-road comfort. Around the same time, we plan to install a mechanical locker like the OX Locker to the rear differential.
We plan to mount a Curt front receiver hitch to the front of the van and use a winch mount plate to have a winch that is movable between the front and rear of the van. We plan to install a Badlands 12,000 pound winch.

We are beyond excited to start this new adventure and build this van into our next travel vehicle. We will bring you along on the blog, social media, and on the YouTube channel.