Gus the Bus: Ram Promaster Camper Van (sold)

The Why Behind the Build

One of the more enjoyable aspects of building a custom camper van is bringing a far-off vision to life. Our design goals for this Ram Promaster van—which is affectionately known as Gus the Bus—was to maximize the cargo space for daily driver purposes, create a warm and welcoming vibe by using natural materials and colors, and keep the overall design simple. And perhaps most important, it needed to be functional across a wide range of outdoor and everyday activities.

Interior

Insulation

After hours of research and much back and forth, we decided that Polyisocyanurate rigid foam insulation would be the best option for our camper van insulation needs. Specifically, we used 1-inch Thermasheath Rmax boards throughout the Ram Promaster camper van. Insulation is a highly-debated topic, but we chose the polyiso for its ease of installation, high R-value, and resistance to moisture (something that’s very important for camper vans).

Roof Vent Fan 

Alluded to above, moisture buildup is an ongoing battle while camping in damp or wet environments (which is all too common in the PNW). Not to mention, a camper van without a fan gets smelly pretty darn fast. Luckily, a quality roof top fan goes a long ways in alleviating both problems. We chose the highly-rated Maxxair MAXXFAN 6200K (which is the same as the 5100k but with a dark colored rain shield) for our ventilation needs. See our roof vent fan guide for why we think it’s the best.

Ceiling and Walls 

A cozy feeling camper van was high on our must-have list, and as such, we decided to go with cedar tongue and groove boards for the ceiling and walls. We chose cedar for its natural resistance to mold, the inviting smell, and cool looking grain and color. If one thing caught most people’s attention while checking out the van, the tongue and groove was certainly it. Best of all, it’s relatively quick and easy to install.

Upper and Lower Cabinets

Continuing the natural look and feel of the tongue and groove cedar ceiling and walls, we used high-quality Baltic Birch plywood for the upper and lower cabinets. The lower cabinets and bench—which needed to support our weight—were built out of strong 3/4" thick sheets of plywood. While most companies go with a lighter weight variety, we felt the added thickness would be worth it in the long run.

For the upper cabinets, we decided that 1/2" birch plywood would be plenty strong. Not to mention, it kept overhead weight to a minimum and made for a better driving experience overall. Instead of the doors opening up sideways—like to lower cabinets—we opted for them to swing up. To accomplish this, gas struts were used to support the doors, which kept them out of the way while reaching for clothing items or blankets.

Folding Bed

Mentioned above, we wanted to be able to take full advantage of the Promaster’s large cargo area. To do this, we decided that a hinged bed system was the best way to achieve this. We had a few requirements: it had fold up and out of the way when not in use, be operable by one person, and we didn’t want to store any part of it in a garage or apartment. To meet our needs, we used 80/20 extruded aluminum for the frame, industrial hinges where it folded, and 1/4" plywood for the platform. All said, we’re very pleased with the finished product.

Electrical 

To keep things as simple as possible, we decided to go with a complete Goal Zero setup. Specifically, this Promaster camper van was equipped with a Boulder 100 solar panel and a Yeti 1000 Lithium Portable Power Station. Some may argue that Goal Zero products are overpriced and you can cobble something together for much less (which is true), but it’s impossible to beat the simple plug-and-play nature of their systems. Time is money and everything was insanely quick to install.

Each person's power needs are different, but this setup was ideal for week-long trips and provided more than enough juice to run a small microwave, ceiling lights, and a roof vent fan. It also charged our phones, bluetooth speaker, and laptops while on the go. All said, we were more than satisfied with their products.

Cooler and Food Storage

In an effort to keep the overall cost down and the design simple, we decided to go with a high-quality cooler over a more expensive fridge option. The Yeti Tundra 45 Cooler was the perfect size for long road trips, and the clean lines blended in nicely with the rest of the build. Not to mention, the Tundra 45 kept ice frozen for days and was the perfect companion most of the time. Having said that, we certainly see the value in an electric fridge (no more stopping for ice) for full-time travelers. If vanlife freedom is what you seek, then we think the Dometic CFX 50W Fridge is the way to go. The brand has been in the game for longer than most, it’s a super efficient model, and it has sufficient space for multiple days between services.

Exterior 

Awning 

Perhaps one of our favorite purchases for the entire Ram Promaster camper van build was the Thule HideAway Awning, which really brought the whole package together. It’s hard to explain, but hanging out in front of your van without an awning just doesn’t feel as good as when you have one. And the benefits of having that extra coverage are never ending. Be it for shade in the summer or protection from rain in the winter, a camper van awning makes a whole lot of sense.

Tires 

We have a tendency to take the road less traveled, and because of this, we’ve always put a lot of value in high-quality aggressive tire. Although a bit much for the average vanlifer, Goodyear’s Duratrac Tire has been a favorite among overlanders for years. They’re one of the few all-terrain tires that offer a nice mix of on-road manners with off-road chops. We traveled to a number of remote locations in the Ram Promaster—including ski hill parking lots and backcountry basecamps—and they never let us down. If you like the idea of the Duratracs but are looking for a slightly more road-friendly option, we think Falken’s Wildpeak AT3W is the way to go. In the end, both tires are solid options, just make sure you go with the load range “E” model to handle the weight of your van.

Hitch 

We prefer to haul bikes inside the van when possible—especially when traveling long distances—but having a hitch and rack for shorter jaunts is indispensable (we think Thule’s T2 Pro XT is currently the best). A hitch rack is quicker to load and unload and it’s an easy way to increase capacity if you need to bring more than one bike each. We initially started off with the stock hitch, but then quickly realized that it only attached to the face of the bumper and the bikes bounced around a lot. After a couple of months of nerve-wracking backroads driving—we had visions of bikes flying off the back—we upgraded to the frame-mounted Draw-Tite Max Frame Receiver. All told, it’s significantly sturdier and worth every penny.