10 Van Build Mistakes We Made (and What We’d Do Differently)

Van Build

Nov 27

Hi, I’m Lauren Stone — and if you’re new here, welcome! My husband Jason and I have spent the last year converting our 2019 Ram ProMaster 3500 (which we lovingly call Sam) into our full-time home on wheels.

We now live on the road full-time with our two dogs, Miles and Potato, after selling our house and putting everything we own into a tiny 5x5 storage unit somewhere in the Carolinas.

Last week, I shared a full van tour, showing how we transformed this blank cargo van into our cozy little home. But today, I want to share something that most van lifers don’t always talk about: the things we regret or would do differently if we could start over.

These aren’t deal-breakers — we absolutely love our van — but they’re lessons learned that could help anyone building or planning their own camper van conversion.

1. Not Adding Flares for Extra Bed Space

One of the biggest investments we skipped (and kind of regret) was not adding flares. Flares are extensions added to the rear sides of your van that give you a few extra inches of sleeping width — which makes a huge difference.

Jason is a little taller than me, and while we technically fit side-to-side, adding flares would have allowed us to stretch out and sleep more comfortably, especially since our dogs insist on sharing the bed. Sleep is everything in van life, and a few inches of extra space would’ve been worth every penny.

2. Not Tightening Up Dimensions During the Build

We went into this van build with zero experience — and it shows in a few spots! Some of our cabinet dimensions are just a bit off, and we ended up with small gaps and squeaky doors.

For example, our toilet bench fits a little too close to our table, and there’s wasted space inside the bench where we could’ve added more storage. In tiny spaces, every centimeter matters. If we ever do a second build, we’ll definitely be more precise with our measurements.

3. Choosing the Wrong Table Base Height

We built a DIY bench and adjustable table that lowers to become part of our lounge area. It’s great in theory — but the table sits too low because we didn’t factor in the cushion height when measuring.

There was a slightly more expensive table base I skipped to save money, and now I wish I hadn’t. A couple of extra inches would’ve made the space far more functional for eating and working. Lesson learned: sometimes the “splurge” items end up being the most practical.

4. Poor Bench Design and Lost Storage Space

Our bench area could have been so much better designed. We built it around a support post that runs right through the middle, which makes it awkward and eats up valuable storage space.

If we did it again, we’d redesign it completely to create one large, easily accessible storage compartment instead of two smaller, less functional ones.

5. Forgetting Gas Struts for Cabinets and Benches

If you’re building a van, add gas struts to your cabinets and benches! We didn’t — and now every time I open one of the upper cabinets in our van, I’m holding it up with my head while trying to grab dog food or supplies.

Installing struts looked complicated at the time, but they’re so worth it. Jason promised me that adding them will be my Christmas present this year!

6. Poor Placement of Our Outdoor Shower Port

We love having an outdoor shower in our van, but the placement? Not so much. We installed the water port under our fold-out table, which means every time we want to use it, we have to lift the table.

If we had placed it on the outside of the van near the sliding door, it would be so much easier to access. Lesson learned: plan functionality over aesthetics — and always think about how you’ll actually use it day-to-day.

7. No Good Spot for the Trash Can

Trash storage is one of those small but surprisingly big van life challenges. We initially planned to store it under the sink, but plumbing took up too much space. Our current solution is a small trash can held by a bungee cord, but it’s not ideal — it gets in the way and doesn’t open fully.

If you’re planning your layout, seriously think through where your trash will go. It’s the kind of daily-use item you’ll notice immediately if it’s inconvenient.

8. Skipping a Sliding Door Window

We wish we had added a window on the sliding door. While we get plenty of light, there are times when we need to cover certain windows for privacy or heat management, and having that extra window would help with airflow and lighting balance.

It’s not a major regret, but something we’d definitely do differently next time.

9. Installing a 12V Outlet We Never Use

We added a 12V outlet up front “just in case” — but haven’t used it once. What we should have installed instead were USB-C and USB ports near our work area. Now, whenever we need to charge something, we either have to turn on the inverter or reach awkwardly to the back of the van.

If you’re planning your electrical system, think about where you’ll actually use your devices day-to-day.

10. Stressing Over the Small Stuff

Last but not least — I wish I hadn’t obsessed so much over the little imperfections. The uneven drawer faces, tiny scratches, or visible screw holes used to drive me crazy.

Now that we’re actually living in the van, I couldn’t care less. It’s cozy, functional, and feels like home. Perfection doesn’t exist in van builds — and it’s better to have a slightly imperfect home that you actually use than a “perfect” one you’re afraid to live in.

Final Thoughts

Even with all these “mistakes,” we love our van. Every squeaky cabinet and crooked edge tells the story of how we built our first home on wheels — completely from scratch, with no experience.

If anything, these lessons just make me even prouder of what we’ve created. It’s not Pinterest-perfect, but it’s ours — and it’s allowed us to live a simpler, more intentional life on the road.

Next week, I’ll be sharing a new post all about the things we absolutely love about our van build (because there are so many). Make sure to subscribe to get notified when it goes live — and if you’re planning your own van build, I hope our trial and error helps you avoid a few of these mistakes!

We’re documenting our entire build—from insulation to solar to full-time travel. If you're new here: