How Hilary Spent Just $6,000 on Her Van Build

Interested in van life but not sure it’s affordable?

I recently talked with fellow van lifer Hilary Bird of Outdoorsy Nomad, who bought and converted a 1999 Ford E-250 van into a home for under $6,000. 

She used some pretty clever tricks, budget-friendly options, and DIY solutions to make this happen, clearly showing that you don’t need a massive budget to get out on the road. This also let her sample van life before going all in. 

Hilary explained that she “didn’t want to financially pigeonhole me into it by buying a big, expensive van… I just wanted a van to test out the lifestyle,” 

I know quite a few people who can relate to that.  

So, I’ve taken many of the tips she mentioned in our interview, as well as my own experience with van builds, and laid out exactly how you can plan your first budget campervan build! 

Choosing the Right Van on a Budget

When researching popular van builds, a few vans appear repeatedly, including the Mercedes Sprinter, RAM Promaster, and the Ford Transit. These are all excellent vehicles (I personally love my converted Sprinter van), but they often come with a large price tag. 

If you want to start your van build for just a few thousand dollars, you’ll need to consider some alternative options. 

Some of the more affordable models to use are: 

Ford E-Series (Econoline): This is what Hilary bought to start her van life journey, and it’s an excellent choice for those seeking an economical but reliable option. Most models are similar in size and design to the Dodge RAM ProMaster but at a much cheaper price point. The cargo space is generous, and the camper van’s roof is tall enough for someone under 6’ to stand up. 

Chevy Express: The Chevy Express is a popular choice for an ultra-budget van conversion. The biggest drawback is that they rarely have a high enough roof to stand, but they are very reliable, cheap to repair, and great for stealth camping. Even older ones get good gas mileage, and you can typically get one for just a few thousand dollars.

Nissan NV Cargo: This is a relatively underrated cargo van to choose for your first budget van conversion. It’s a boxy-looking van that’s also great for stealth camping. It has enough space for a couple to comfortably live together and is very good on gas mileage. 

Hilary’s 1999 Ford E-250

When Hilary decided she wanted to try out Vanlife, she chose to buy a 1999 Ford E-250!

Believe it or not, it was actually a former Holiday Inn shuttle bus. She mentioned, “You can still see the Holiday Inn lettering on the top of the van…which gives it a lot of character.” 

She was able to buy the van for less than $3,000, but all the mechanical repairs added another $3,000 to its total cost. 

Unfortunately, this is common when buying an older van with high mileage. 

So, when shopping for a budget campervan, budget a few thousand dollars over the van’s face value so that you can afford any necessary repairs. 

More Ways to Save Money Buying Your First Van

If the goal is simply to get the cheapest van possible, you’ll probably have to settle for a smaller, older van. 

But this isn’t as bad as it sounds. 

For instance, Hilary’s van had a slightly raised roof, which would have been too short for someone over 6 feet tall, but at 5’5, it was “just enough to stand up.” 

Also, older vans aren’t necessarily unreliable. My first Chevy Astro van was built in 1994, and Hilary’s first van was built in 1999. As long as they are from a dependable brand and well-cared-for, you can still find reliable vans from 20+ years ago on Craigslist, Facebook Marketplace, or local dealerships.

Saving Money Each Step of the Way (Essential Components)

Hilary put a lot of effort into saving money to convert her first van. 

Her approach focused on functionality, using reclaimed or repurposed materials where possible and making sacrifices on certain upgrades (things others often see as necessities).  

Instead of building a full kitchen, she uses a propane camp stove. Her sink uses a hand pump instead of a running water system. She also used reclaimed wood from her parent’s house for almost all of the cabinetry, storage, and flooring. 

Here are some ways Hilary saved money, along with some of my own money-saving tips for each area of a budget van conversion.

Flooring / Frame

The foundation of any van build is putting down the flooring and frame, and depending on the material used, this can be surprisingly expensive. 

Hilary saved a lot of money by using leftover spare wood she found at her parents’ house. 

“[The] spare wood….had been sitting in the barn for 20 years,” but it was still quality material for building the frame and flooring of her 1999 Ford E-250. 

She still had to buy some plywood for the walls and ceiling and then coat everything with polyurethane to ensure that it would keep water out of the wood, but this was way cheaper than most van floor options.

Insulation

Insulation is essential to any van build, even if you don’t plan to live in a super cold or warm area long-term.

However, it’s often one of the most expensive parts of the conversion. 

Some DIY solutions can save a little money upfront, but ultimately, the best strategy for saving money on insulation is to use a combination of options. 

You might want to use Havelock Wool (high-quality and non-toxic) around the doors and ceiling, but compromise and use form boards or Thinsulate for insulation on the floor.  

Bed

There’s a lot of debate regarding whether you should have a fixed bed or a bench-to-bed setup. A lot of people will argue that it’s a big hassle to take down and set up your bed every day/night,  

But when you’re on a tight budget, your van may not be the most spacious, and the bench-to-bed setup does maximize space. 

Hilary’s van has a bench-to-bed setup with simple storage drawers built from the reclaimed wood she found at her parents’ house. She also found some quality cushions on Craigslist for just $75 and uses a camping pad under the center of the bed to create even more padding. 

This isn’t as comfortable as a full mattress, but it saves a ton of money upfront!

Kitchen

I know people who spend a lot of money on their van’s kitchen, installing full ovens, electric stovetops, complex plumbing systems, and even small dishwashers. 

But you don’t have to spend thousands of dollars building a kitchen in your van. 

Hilary’s created a fully functioning kitchen for herself out of mostly household items you already have (or could find for a few dollars at a secondhand store). Here are some of the ways she saved money. 

• Propane Camping Stove instead of an Electric Stovetop. 
• Large Yeti Cooler instead of a Refrigerator.
• Hand Water Pump instead of a Complex Plumbing System. 

There are certainly downsides to having a cheap kitchen set up. For example, she mentions, “[the lack of plumbing] gets annoying since I have to manually dump out the sink every day, but if you’re looking to be on the road ASAP, this is just such a quick, easy build.”

Power and Ventilation

These two areas will cost some money, but if you plan to spend extended time in your van, it will be miserable without power and proper ventilation to keep it cool in the summer. 

That said, you don’t need expensive solar panels or a huge power grid to do it. 

Hilary powers her devices with deep-cycle batteries charged by the van’s alternator plus a Jackery 240 portable battery for backup, which she calls “a lifesaver.” 

It’s a few hundred dollars upfront but way cheaper than solar panels. In a single charge, the portable battery can keep her laptop and phone powered up for 3-4 days while off the grid. 

She also uses a MaxxAir RV fan to keep airflow throughout the van. She made this decision during the building process, saying: “The van was smaller and wasn’t going to have amazing insulation [so] airflow was really important to me.”

Storage and Personalization

It’s nice to have high-quality cabinetry and storage areas that maximize every inch of space, but this is one of the easiest parts to DIY. 

You can create shelving using various household items, from mason jars to Velcro-backed pouches and extra trim. 

The same goes for decor. Personalizing your van can be as simple as using extra plywood to build plant shelves and leftover paint for the walls. 

I also noticed that Hilary built drawers without tracks or hinges. They aren’t the most aesthetic or smooth but are 100% functional. She says, “I keep everything from my utensils to my electronics, all my cords, just random things in these drawers.”

When you’re on a shoestring budget, it’s more about practicality than aesthetics. 

FAQ: Common Questions About Budget Campervan Builds

Where Can I Source Affordable Materials?

Back in the day, we used to have to pick through garage sales, bid on eBay, or tiptoe into a sketchy Craigslist meetup. 

It’s a lot easier now with Facebook Marketplace and tons of great secondhand stores throughout major cities. You can find pretty much anything you need (reclaimed wood, insulation, tools, polyurethane, etc.) on FB Marketplace for cheap. You’ll just need a bit of patience. 

Will a Budget Campervan Hold up Long-term? 

Yes, if you keep up with the maintenance of your van, it can last a long time. 

One misconception about van life is that we drive thousands of miles per month and put excessive wear and tear on our vehicles. 

That’s not always the case. 

It’s true that maintenance tends to be an unexpected cost of van life, but it does not decrease the van’s life span any more than a normal vehicle. In fact, many full-time van lifers put the same amount of miles on their van as someone with a 30-minute daily commute to work. 

What Are the Downsides of Budget Builds? 

There are obviously downsides to having a budget campervan, mostly when it comes to convenience and accessibility. 

It’s inconvenient to live without a shower built into the van or a gray water tank and plumbing for a bathroom. Using cheap insulation and wiring could mean you have to replace things sooner, and traveling at the peak of summer/winter might not be as comfortable. 

You also can’t go off the grid as long without investing in solar panels. 

But all these things can be slowly added over time as you save money and can invest more into your van. 

So, What Are You Waiting For?

I hope that, like Hilary of Outdoorsy Nomad, you feel confident taking the leap and trying out van life on a budget. 

You may need to be more patient and resourceful or occasionally prioritize practicality over aesthetics/comfort. Still, you don’t need an expensive, souped-up van to enjoy nature and live life on your terms. 

My partner Tom and I lived in a 1994 Chevy Astro van before recently upgrading to a more luxurious Sprinter van, but we’re so glad that we started when we did rather than waiting until I could afford the Sprinter van. 

If you’re looking to get out on the road, here are a couple of helpful articles to help you get started. 

• The Simplest No-Build Chevy Astro Van Conversion
• How to Build a Campervan: Inspiration, Advice & DIY Van Conversion Resources
• The 8 Most Common First-Time Van-Build Mistakes
• 15 Genius No-Build Van Ideas for Budget-Friendly Adventures
• Chevy Express Van Build: 5 Rad DIY Conversions And Kits