2018 Ram ProMaster 2500 Conversion

Purchased as a blank slate with ~800 miles, this project was executed primarily outdoors during the 2020 COVID shutdowns. The build required converting a bare metal shell into a livable space within a strict 4-month deadline before starting a full-time engineering role in Ohio.

• Framing & Insulation: Designed wooden structural framing attached via sheet metal screws and construction adhesive for vibration damping. Insulated with 1–2" sheep wool for moisture management and sound deadening.
• Fabrication: Cut chassis openings for a roof fan and sliding window. Constructed integrated cabinetry, a fixed bed platform, and under-bed storage in a highly space-constrained volume.
• Repurposed Materials: Reworked timber from deconstructed kitchen cabinets into custom van cabinetry. Implemented compliant, friction-based catch latches to ensure doors remained closed under road loads.

Designed a robust off-grid power system anchored by ~200 Ah of LiFePO₄ batteries. All conductors and fuses were sized based on current draw and run length to mitigate voltage drop and overheating risks.

• Solar Array: Fabricated a custom roof rack using McMaster-Carr L-brackets and marine-grade hardware (nylon insert lock nuts) to mount a 400W array. Validated aerodynamic stability by instrumenting the roof with a GoPro at highway speeds (80 mph).
• Power Management: Integrated an MPPT solar charge controller and a user-switchable 12V-to-12V DC-DC alternator charger for redundancy while driving.
• Safety: Utilized corrugated loom for abrasion protection in corner regions and centralized fusing to isolate faults.