DIY Van Conversion Guide: Installing Electrical and Solar Systems

Happy to have you here reading part three of our Conversion Van Guide.

In our 10-step DIY Van Conversion Guide, we have covered choosing the best van for van life,  planning your van conversion layout, and now we are going over installing electrical and solar systems. 

Starting your DIY van conversion is an exciting adventure, but one of the biggest challenges is setting up a reliable electrical system. 

Whether you're planning weekend getaways or full-time van life, understanding your power needs and selecting the right solar power options—like Renogy and GoPower 3000—is crucial for keeping your van powered on the go. 

Let’s break down the essentials to help you build an efficient electrical system that meets your needs in our 3-of-10-part blog guide for Leisure Travel Vans called “The Van Shark DIY Van Build Guide.”

3 Steps to Understanding Your Van's Electrical System

Think of your van’s electrical setup as a mini power grid with three key components:

1. Power Sources – Electricity generation methods like solar panels, your van’s alternator, or shore power.

2. Energy Storage – The battery bank, which holds power for later use.

3. Power Consumption – Devices like lights, refrigerators, and fans that draw energy from your system.

A well-balanced system ensures you never run out of power, no matter where your travels take you.

Calculating Your Power Needs

Before purchasing equipment, you need to estimate your daily energy consumption. Here’s how:

✅ List Your Devices – Write down all electrical appliances (e.g., fridge, lights, water pump) and their power ratings in watts. 

✅ Calculate Usage – Multiply each device’s wattage by the hours used daily to get watt-hours (Wh).

 ✅ Determine Battery Capacity – Add up all watt-hours to find the minimum battery size needed to keep your van running smoothly.

For example, if your total energy consumption is 1,200 Wh/day, you’ll need at least a 200Ah lithium battery (assuming an 80% depth of discharge).

Choosing the Right Power Sources for Your DIY Van Conversion

A solar-powered setup is a popular choice for van dwellers, but many also use a combination of charging methods:

☀️ Solar Panels (Renogy & GoPower 3000) – Efficient, eco-friendly, and great for long-term off-grid living. 

🚐 Alternator Charging – Charges your battery while driving, providing backup power on cloudy days. 

⚡ Shore Power – Plugging into an external outlet at campsites for fast charging and running high-power appliances.

Most van lifers combine these methods to ensure a steady power supply in different environments.

Battery Selection: Lithium vs. Lead-Acid

Your battery bank is the heart of your system. Here are the main options:

🔋 Lead-Acid Batteries – Budget-friendly but heavier and less efficient (shouldn’t be discharged below 50%). 

🔋 Lithium Batteries (LiFePO4) – These are More expensive but lighter, longer-lasting, and capable of deep discharges (up to 80-90%).

For full-time van life, lithium batteries are a smart investment due to their durability and faster charging capabilities.

Wiring & Safety Considerations

Proper wiring is essential for safety and efficiency:

✅ Wire Sizing – Use cables thick enough to handle the power load and prevent overheating. 

✅ Fuses & Breakers – Install fuses to protect your system from electrical overloads. 

✅ Grounding – Essential for preventing shocks and electrical interference. 

✅ Secure Connections – Loose connections can cause power loss and increase fire risks.

6-Step Van Conversion Electrical Installation Guide

1. Plan Your System – Create a wiring diagram including all components. 

2. Install Batteries – Secure them in a well-ventilated, accessible location. 

3. Mount Solar Panels – Attach panels to the roof and run cables to the charge controller. 

4. Set Up Charging Sources – Connect the alternator and shore power inputs. 

5. Wire Your Devices – Connect appliances to the fuse panel with appropriate wiring. 

6. Test Everything – Check for voltage drops and ensure all systems work before heading off-grid.

Power Up Your Van Life with Ease!

Installing an electrical system may seem overwhelming, but with pre-labeled kits and step-by-step instructions from brands like Renogy and GoPower 3000, the process becomes much more manageable.

Whether you’re upgrading a Mercedes Sprinter van or a leisure travel van, a well-designed system will keep you powered up for all your adventures.

🔋 Ready to build your ultimate van setup? Visit VanSharks.com for the best conversion kits and expert guidance!