Sprinter Camper Van: DIY Build Resources

Mercedes Sprinter Van

Sprinter Camper Van: DIY Build Resources

This page gathers useful information related to the Mercedes Sprinter Van aimed at the DIY campervan builders in mind. Although we personally converted a Ford Transit Van, there are a lot of similitudes between any platform (Transit, ProMaster, Sprinter, Nissan NV) and most of what you'll find on our website is applicable to any camper build, really. So below you'll find data specific to the conversion of Sprinter camper van, hope that helps!

Logo-FarOutRide-512px

Disclosure: This post contains affiliate links, which means that if you click a product link and buy anything from the merchant, we will receive a commission fee. The price you pay remains the same, affiliate link or not.

Sharing our website with others and buying products through our links is the best way to say thanks if we were of any help for your conversion! Thanks for supporting us and for keeping this website alive 🙂

Alternatively, use these links to search for any product (or visit our Say Thanks! page):

Portrait

1- Sprinter Van Overview

Mercedes Sprinter Van Side View
Mercedes Sprinter Van Rear View

1.1- Build & Price

Style

  • Cargo Van
  • Passenger Van

Length

  • Standard 19.5 ft (144" WB)
  • Long 22.8 ft (170" WB)
  • Extended 24.15 ft (170" WB)

Height

  • Standard Roof (96.3")
  • High Roof (110")
  • Super-High Roof (120.1")

Engines

  • 2.0L Turbo (Gas)
  • 3.0L Turbo (Diesel)

Drivetrain

  • RWD
  • 4x4

1.2- Exterior Dimensions

1.3- Interior Cargo Dimensions

To build a DIY campervan is one thing; to maximize the livable space is the real challenge! Here is your starting point (interior cargo dimensions) if going for a Sprinter Van:

Standard Length (144WB),
Low Roof:

Long Length (170WB),
High Roof:

Extended Length (170WB), High Roof:

1.4- Repair And Maintenance

Opinions toward the Mercedes Sprinter are very polarized. You get a high-end vehicle from a high-end brand, it's all good right? Well, it's a bit more complicated than that. The saying "more features = more potential for failure" seems to hold true for the Sprinter. And once you run into issues, you get high-end bills as well...

Sprinter Van Annual Repair Cost

$ 1,778 USD

Ford Transit Annual Repair Cost
$ 866 USD
ProMaster Annual Repair Cost
$ 859 USD

1.5- Manuals

Online discussion forums and Facebook groups are great resources, but not that much... there is a lot of misinformation in those. Why not check your facts straight from the owner's manual or from the Body and Equipment Guideline (BEG)? You'll find answers to most of your questions, from a credible source! Indeed, no one knows the product better than the OEM (Original Equipment Manufacturer). "How-To Tap for Auxiliary Power?", "Where are the no-drill zones?", etc: it's all in there. Download the PDF files and use the "SEARCH" function:

Sprinter Van Owner's Manual
Sprinter Van Owner Manual
Sprinter Van Body and Equipment Guideline (BEG)
Sprinter Body And Equipment Guideline (BEG)

1.6- Sprinter VS Transit VS ProMaster VS Nissan

Sprinter, Transit, ProMaster, Nissan... not sure which van is the best for a campervan conversion? We gathered some data about each model to help you make up your mind: overview, build & price, exterior dimensions, interior dimensions, repair cost, etc. This way:

2- Tires for Sprinter Van

The 2500 Sprinter Van comes equipped with 245/75R16 tires, but most folks looking to go off the beaten track (like us) choose to upgrade the factory tires for BFGoodrich KO2 245/75R16 All-Terrain tires. We've been running them on our van since 2016 and we're not looking back (our first set last 45K miles, we are currently on our second set):

BFGoodrich KO2 LT245/75R16 E Tires
Our BFGoodrich KO2 Tires Review

3- Electrical Wiring Diagram for Sprinter Camper van

We designed our electrical system with flexibility in mind. It can be downsized (e.g. no shore power, no alternator charging, no 120V, etc.) or up-sized (more solar, more battery bank, etc.). We also made sure it can fit in pretty much any vehicle (Transit, ProMaster, Sprinter, Skoolie, etc.). The only difference is most likely how to tap for auxiliary power (alternator charging): check out section 3.4 below for Sprinter's specific information.

3.1- Wiring Diagram

hover your cursor (desktop) or tap (phone/tablet) on each component to learn more.

3.2- Items List

1- Inverter:
#ItemDescriptionQuantityView on Amazon
11000W InverterSamlex PST-1000-12 PST Pure Sine1View
2Remote Control for InverterSamlex RC-15A for 600W/1000W Inverter1View
3Cable, 2 AWG, 5 ft Black + 5 ft RedWindyNation1View
4Lugs, 2 AWG Cable, 5/16″ RingConnect to Terminal Fuse Block and Bus Bar (Pack of 2)1View
5Terminal Fuse, 175ABlue Sea (To protect inverter’s cable)1View
6Terminal Fuse BlockBlue Sea (Connects directly on the Bus Bar. Holds the Terminal Fuse)1View
2- Battery:
1LiFePO4 200 AhBattle Born LiFePO4 100 Ah 12V2amzn.to/2l6YuQQ
22/0 Cable in 5/16 lugs, 1 feet Red + 1 feet BlackWindy Nation Copper Cable1amzn.to/2D6EGFX
3- Solar:
1350W SolarNewPowa 175W Mono Panel2View
2Extension Cables, 8 AWG, 15 ft Red + 15 ft BlackWith MC4 Connectors1View
3Double Cable Entry GlandFor 8 AWG or 10 AWG Cable1View
440A Breaker/Switch, Surface MountBetween Panels and MPPT Charger1View
5MPPT Solar ChargerVictron 100|30 SmartSolar MPPT1View
640A Breaker/Switch, Surface MountBetween MPPT Charger & Battery1View
7Heat Shrink Terminal Ring, 8 AWG Cable, 5/16″ RingConnect to Bus Bar (Pack of 3)1View
8Heat Shrink Terminal Ring, 8 AWG Cable, 1/4″ RingConnect to Breakers (Pack of 3)2View
4- Alternator:
160A Battery-to-Battery Charger (B2B)Sterling Power BB12601View
270A Breaker/Switch, Surface MountBlue Sea 285-Series2View
3Cable, 4 AWG, 15 ft Black + 15ft RedWindyNation1View
4Lugs, 4 AWG Cable, 5/16″ RingConnect to Bus Bar (Pack of 2)1View
5Lugs, 4 AWG Cable, 1/4″ RingConnect to Breakers (Pack of 2)2View
5- Shore:
150A ChargerSamlex SEC-1250UL 12V1View
260A Breaker/Switch, Surface MountBetween Charger and Bus Bar1View
3Cable, 8 AWG, 5 ft Black + 5 ft RedWindyNation1View
4Heat Shrink Terminal Ring, 8 AWG Cable, 1/4 RingConnect to Breaker (Pack of 3)1View
5Heat Shrink Terminal Ring, 8 AWG Cable, 5/16″ RingConnect to Bus Bar (Pack of 3)1View
6- Main:
1Terminal Fuse, 250ABlue Sea (Catastrophic Fail Safe)1View
2Terminal Fuse BlockBlue Sea (Connects directly to battery post. Holds the Terminal Fuse)1View
3System SwitchBlue Sea (Main System Switch)1View
4Bus Bar (250A, 4 studs)Blue Sea2View
5Cover for Bus Bar (for 250A 4 studs)Protect the Bus Bar2View
640A Breaker/Switch, Surface MountBetween Fuse Block and Bus Bar1View
7Fuse Block (12 circuits)Blue Sea (12V Distribution Panel)1View
8Fuses KitAssorted Fuses (2A 3A 5A 7.5A 10A 15A 20A 25A 30A 35A)1View
9Battery MonitorVictron BMV-712 with BlueTooth1View
10Cable, 2/0, 5 ft Black + 5 ft RedBetween battery and Bus Bar1View
11Lugs, 2/0 Cable, 3/8″ RingConnect to System Switch and Shunt (Pack of 5)1View
12Lugs, 2/0 Cable, 5/16″ RingConnect to Bus Bar, Terminal Fuse Block and Battery (Pack of 5)1View
13Cable, 8 AWG, 5 ft Black + 5 ft RedBetween Bus Bar and Fuse Block1View
14Heat Shrink Terminal Ring, 8 AWG Cable, #10 RingConnect to Fuse Block (Pack of 3)1View
15Heat Shrink Terminal Ring, 8 AWG Cable, 1/4″ RingConnect to Breaker (Pack of 3)1View
16Heat Shrink Terminal Ring, 8 AWG Cable, 5/16″ RingConnect to Bus Bar (Pack of 3)1View
17Heat Shrink Tubing Kit (with adhesive)To protect lug after crimping1View
7- Hardware:
112 AWG Black/Red Duplex Cable (12/2), Ancor Marine Grade100 feet1View
214 AWG Black/Red Duplex Cable (14/2), Ancor Marine Grade100 feet1View
3Heat Shrink Terminal Ring, 12 AWG Cable, #8 RingTo connect to Fuse Block (25 Pack)1View
4Heat Shrink Terminal Ring, 14 AWG Cable, #8 RingTo connect to Fuse Block (25 Pack)1View
5Heat Shrink Butt Connector, Ancor MarineTo connect to Loads (75 Pack Kit)1View
6Heat Shrink Disconnect, 10-12 AWG Cable, 1/4″ Tab, Female
To connect to certain loads (i.e. 12V Sockets) , to make “removable” connections (i.e. Fridge, LEDs) and to connect cable of different gauge together (i.e. LED Dimmer) (25 Pack)
1View
7Heat Shrink Disconnect, 10-12 AWG Cable, 1/4″ Tab, Male1View
8Heat Shrink Disconnect, 14-16 AWG Cable, 1/4″ Tab, Female1View
9Heat Shrink Disconnect, 14-16 AWG Cable, 1/4″ Tab, Male1View
10Heat Shrink Disconnect, 18-22 AWG Cable, 1/4″ Tab, Male1View
113M Scotchlok Quick Splice with Gel (14 AWG stranded)We used that to parallel our LED lights (25 Pack)1View
12Split Loom Tubing, 3/8″ diameter 20 feetTo protect wire bundles1View
13Split Loom Tubing, 1/2″ diameter 20 feetTo protect wire bundles1View
14Split Loom Tubing, 3/4″ diameter 20 feetTo protect wire bundles1View
15Nylon Cable Clamps KitTo secure cable/split-loom to wood1View
16Zip Tie Mount with AdhesiveTo secure cable/split-loom to metal1View
17Nylon Zip Ties KitTo secure cable/split-loom1View
18Rubber Grommet KitTo protect wire from sharp edge (going through metal hole)1View
8- 12V Loads:
1Maxxair 6200K Roof FanSee our Installation or Review article1amzn.to/2qJCbA1
2LED Ceiling LightsSee our Installation and Review article3amzn.to/2vpyyVs
3Dimmer for LED (PWM), 12V, SliderTo control intensity of LED lights1amzn.to/30dDyak
4Blue Sea 12V Socket 4amzn.to/2JVPypv
5Shurflo Revolution Water Pump, 3 GPMSee our Installation article1amzn.to/2J9NqZQ
6ON/OFF Switch for Water Pump 1amzn.to/2Oiyhvy
7Webasto Air Top 2000 STC Gasoline HeaterSee our Installation article1eBay
8Propex HS2000 Propane HeaterSee our Installation article1eBay
9Novakool R5810 Fridge, 12V only5.8 cubic feet1Novakool
10Sirocco ii Gimbal Fan, 12VSee our Review article1amzn.to/2HKy7HR
11Nature’s Head Composting ToiletSee our Installation or Review article1amzn.to/2qJOsEA
12Propane Solenoid Shutoff ValveSee our Propane System Guide1eBay
13ON/OFF Switch for Propane SolenoidSee our Propane System Guide1amzn.to/2LB5Gjr

3.3- Electrical System Design Guide

1- Calculate Your Power Usage
2- Size Your Items (Inverter, Battery, Solar, Alternator, Shore)
3- Make A Wiring Diagram
4- Make An Items List that fully defines your electrical system
  • Find Your Power Usage and Size Your Items (solar, battery, etc.) With Our Online Calculator
  • Select Your Items Automagically
    (Or Manually)
  • Download Your Wiring Diagram
  • Review Your Items List and transfer it to your Amazon Cart
    (Fully Defines Your Electrical System!)

3.4- Power Tapping

For current draw larger than 25A (B2B charger, fuse box, etc.), it is mandatory to use an auxiliary battery (option E2M or E21) and to connect as follows:

Sprinter Power Tapping Option 2 (page 1)
The pictures above are extracted from the Body and Equipment Guideline, page 246, 247 & 248. Make sure to read these pages for manufacturer recommendations and limitations:

4- Water Plumbing Diagram for Sprinter Camper van

Our water system is designed with simplicity in mind and it can be installed in a Sprinter Van: it's fairly easy to install and simple to winterize. It can also be used below freezing temperatures (e.g. for skiing) assuming all the plumbing is install on the hot side of the van (i.e. inside). Check out our Water System "Design Guide" for more.

4.1- Water Plumbing Diagram

4.2- Water System Design Guide

5- Propane Diagram for Sprinter Camper van

Once again, our propane system can be fitted in a Sprinter Campervan. The 20lbs (BBQ-style) is easy to fill anywhere and is located inside a vented locker (per marine regulations) for maximum safety. Neat!

5.1- Propane Diagram

5.2- Propane System Design Guide

Propane System Design Guide

6- Sprinter Camper van Build Guide

We obsessively documented our campervan conversion in our Build Journal: material, products, techniques, lessons learned, etc. IT'S ALL IN THERE! Our van is built from a Ford Transit, however most of our conversion process can be applied to a Mercedes Sprinter:

7- Crossnut Size for Sprinter Van

We don’t like drilling holes in our van, as it could attract rust on bare edges, spread metal chips all over (almost impossible to remove and they’re the perfect rust ignition point), interfere with the van’s electronics (see BEG)! To prevent drilling holes, we used Crossnut through our conversion. Most pre-drilled holes in the Sprinter Van cargo area accept 5/16″ diameter Crossnut (amzn.to/31vS654), but some holes also accept 1/4″ (amzn.to/2MuKjk3) and #10 (amzn.to/2P4Muwb) crossnut. Check out the following article for more info (benefits, installation, tips):

8- Sprinter Camper Van DIY Conversion Accessories

Sprinter NCV3 High/Low Roof Vent Adapter
Under Vehicle Battery Box (NCV3 Sprinter)
Door Prop (Sprinter/Transit) Review
Minicell Floor Insulation Packages (NCV3 Sprinter)
RB Components Sprinter Van Storage Shelf
Vancillary DIY Sprinter Van Headliner Shelf Kit
Sprinter T-Vent Passenger Sliding Door
RB Components Sprinter Van Wall Cabinet

STAY IN TOUCH!

Join 25,000+ followers via Facebook, Instagram, YouTube, Pinterest, Patreon or e-mail:

about us

Nice To Meet You.

Hello! We’re Isabelle and Antoine 🙂 In 2017 we sold our house (and everything in it), quit our engineering careers and moved into our self built campervan. We’ve been on the road since then and every day is an opportunity for a new adventure; we’re chasing our dreams and hopefully it inspires others to do the same!

Leave a Comment

This site uses Akismet to reduce spam. Learn how your comment data is processed.