This section provides a breakdown of the weight, the cost, and the labor for the full conversion. The weight includes the van + conversion weight + payload.
The summary might be helpful if you are planning your own conversion, but be careful to account for differences between what we did and what you plan to do.
The quick summary is that the van starts at 4730 lb as delivered, the camper conversion adds 1030 lbs, and the payload (two people, water, propane, groceries, …) add another 970 lbs bringing the full up ready to travel weight to about 6700 lbs — well under the allowed weight of about 8600 lbs.
|1034 (1)||154||880||Conversion parts(beds, tanks, galley, paneling, …|
Empty Weight After Conversion
|5764||3167||2597||Weight of converted van without payload|
|971||546||425||Payload (people, water, groceries, propane, junk)|
Total Trip Weight
|6734 lbs||3713 lbs||3022 lbs|
Note (1): Includes just about everything including 50 lb PV panel that has not be mounted yet. We might add some small storage cabinets and other odds and ends later.
I did weigh the van and get front and back axle weights and a total weight. There was a modest discrepancy between the actual scale weight of the converted van and the sum of the weights I estimated for each part (flooring, insulation, …), but only about 60 lbs.
The maximum allowable weight for the ProMaster 1500 model is 4630 lb front, 5291 lb back, and a total of 8550 lbs — so, we have 900+ lbs margin on front axle, and 2200+lbs margin on back axle, and 1800+ lbs on total weight. So, it looks like the 1500 model on the 136 WB can easily handle a complete conversion.
Breakdown of Conversion Weight, Cost and Labor
|Item||Cost ($)||Labor (hr)||Weight (lb)|
|Insulating||$360||6||20||Weight is based on what 1 inch of polyiso would weigh|
|Electrical incl solar||$1,507||24||236||batteries, inverter/charger, PV …|
|Windows||570||12||36||Window weight minus sheet metal removed|
|Curtains||$109||2||6||EuroCamper on windshield, Reflectex rest.|
|Flooring||$204||20||96||Vinyl floor with polyiso insulation.|
|Paneling||$180||36||99||Hardboard wall and ceiling paneling.|
|Galley (incl stove, fridge, sink)||$1,120||24||179||Includes fridge ($630), sink, stove cabinets|
|Fresh and grey waters systems||$270||10||42||Includes fresh and grey tanks, plumbing and pump|
|Beds and storage||$349||24||175||Includes platform, mattresses, hinges, propane compartment|
|Ventilation fan||$278||4||12||Fancy fan was $268|
|Furnace||$430||3||23||Just furnace, no supports etc which are incl in galley cabinet|
|Propane system||$60||2||28||This is empty tank and plumbing (cabinet in bed weight)|
The detailed pages for each area (Insulation, Paneling, …) has a breakdown for the weight, cost and labor for that area.
The labor column adds up to 185 hours, but I’m thinking this is on the low side. I did try to keep track of time spent as I went along for each job, but I’m guessing I missed some hours. One thing it does not count for sure is the many hours of internet research and trying to figure out what will work.
The total calendar time for the conversion was 6 months. This was from starting the insulation in July of 2014 to our first shake down trip to Utah with the finished conversion in January of 2015. This also makes me suspicious of the 185 hours number above, as this only works out to about 32 hours per month, and I believe I spent more time on it than that.
Note that the weights for your conversion may differ significantly from these depending on what you include.
February 8, 2015, June 25, 2015, November 16, 2019.