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Van Electrical Designer
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Van Electrical System Designer
Mod It Design · v1.0
Licensed to:
Electrical System
🔧Build Planning
0Your Van
1Appliances
2Battery Bank
3Solar
4Alternator
5Inverter
6Wiring
7Summary

Select your van to pre-fill sensible defaults for cable run lengths, solar capacity, and alternator output — and get model-specific design tips and electrical warnings tailored to your build.

VW T5
2003–2015
Compact
VW T6/T6.1
2015–present
Compact
Sprinter
W906/W907
Large
Ford Transit
MK7/MK8
Large
Ducato/Boxer/Relay
2006–present
Large
Crafter/MAN TGE
2017–present
Large
Trafic/Vivaro
2014–present
Compact
Transit Custom
2012–present
Compact
Vito/V-Class
W447 2014+
Compact
Other / Custom
Any van
Custom

Design tips for your van

    Electrical gotchas to know

      How to use this step

      Select your van model above. The tool will:

      • Pre-fill cable run lengths for your van's typical layout
      • Set default B2B charger rating based on your alternator
      • Show max solar capacity based on roof dimensions
      • Warn you about known electrical issues for your model
      • Give tailored design suggestions for your specific build

      You can override any pre-filled value in later tabs. The van selection is just a starting point.

      List every electrical device in your van. Enter the wattage (check the label or manual) and how many hours per day you expect to use it. The tool calculates your total daily energy need in Wh — this number drives every other calculation.

      Appliances & devices 0 Wh/day
      DeviceWattsHrs/dayWh/day
      Not sure of the wattage? Check the device label, the manual, or search "wattage of [device name]". For 12V devices, multiply amps × 12 to get watts. A clamp meter is the most accurate method.
      Total daily consumption
      0Wh/day
      Add your appliances to get started.
      Largest single load
      0W
      Used to size your inverter.
      Common wattages
      12V compressor fridge35–60W
      LED strip lights (per m)5–15W
      Laptop (charging)45–90W
      Phone charging10–20W
      MaxxFan / roof vent15–30W
      Diesel heater fan10–40W
      12V water pump60–100W
      Coffee machine (240V)900–1500W

      Your battery bank stores the energy you need to run through the night or on cloudy days. The key decisions are chemistry (which determines how much you can safely use), and how many days of autonomy you need without charging.

      Battery chemistry
      LiFePO4
      80% usable
      Lithium iron phosphate. Lighter, longer life, more expensive. The modern standard.
      AGM
      50% usable
      Sealed lead acid. Heavier, cheaper, shorter life. Good budget option.
      Gel
      50% usable
      Similar to AGM. Slightly better cycle life. Requires careful charging.
      days
      2–3 days covers most UK conditions. More autonomy = bigger (heavier, costlier) battery.
      %extra capacity
      LiFePO4 recommendation: For most van builds, 2× 100Ah LiFePO4 in parallel (200Ah total, 160Ah usable) covers 400–500Wh/day comfortably. They cost more upfront but last 10× longer than AGM.
      Recommended battery capacity
      0Ah
      Usable capacity needed
      0Wh
      Battery sizing explained

      The formula is:
      (Daily Wh × Days) ÷ DoD% × Margin

      Ah capacity assumes a 12V system. If using 24V, the Ah figure halves (but the Wh energy is the same).

      Solar panels recharge your batteries using daylight — not just direct sun. The amount of energy they produce depends on panel wattage, how many hours of usable light you get, and system losses from wiring and the MPPT controller.

      Panel & system settings
      W
      Common sizes: 100W, 150W, 200W, 400W panels. Multiple panels can be wired in series or parallel.
      %total losses
      20% is realistic for a well-installed van system (MPPT ~6%, wiring ~3%, temperature ~8%, shading ~3%).
      Winter
      1.5
      peak hrs/day
      Spring
      2.5
      peak hrs/day
      Summer
      5.5
      peak hrs/day
      Autumn
      2.5
      peak hrs/day
      UK reality check: In winter, solar alone rarely covers a full build. Pair with a B2B charger (alternator) or mains hookup for November–February.
      Daily solar generation
      0Wh/day
      Solar coverage
      0%
      Panels needed to cover load

      A B2B (battery-to-battery) charger lets your van's alternator charge your leisure battery while you drive. It protects your starter battery and delivers a proper charge profile. This is your most reliable charging source when solar is limited.

      B2B charger settings
      A
      Common sizes: 20A, 30A, 40A, 60A. Set to 0 if not fitting a B2B.
      hrs
      Sizing tip: A 30A B2B at 12V delivers 360W. Over 2 hours driving that's 720Wh — enough to cover a fridge, lights, and phone charging for a full day.
      Daily B2B charge contribution
      0Wh/day
      Total daily charging (solar + B2B)
      0Wh/day

      An inverter converts 12V DC battery power into 240V AC mains power for laptops, coffee machines, and other household devices. Size it for your largest expected load, with headroom for the startup surge.

      Inverter inputs
      ×
      Most motors and compressors need 2–3× their running wattage to start. 2× is a safe default for most builds.
      Pure sine wave only. Modified sine wave inverters are cheaper but damage sensitive electronics including laptops, phone chargers, and diesel heater controllers. Always buy pure sine wave.
      High-draw devices: Coffee machines (1000–1500W), hairdryers (1500W+), and kettles (2000W+) need large inverters and draw heavily from your battery. A 1000Wh fridge-worth of power can vanish in under an hour of kettle use.
      Recommended inverter size
      0W
      Largest 240V load detected
      0W
      From your appliance list (240V devices only)

      Undersized cables cause voltage drop, wasted energy, and in serious cases, fires. Enter the cable run length for each key circuit and the tool calculates the minimum cable size to keep voltage drop under 3% — the accepted standard.

      Cable run lengths
      m
      m
      m
      m
      Always fuse close to the source. Fit an ANL fuse or fuse holder within 30cm of the positive battery terminal on every high-current cable run.
      Recommended cable & fuse sizes
      CircuitCurrentMin cableFuse
      Voltage drop formula: Drop (V) = 2 × length × current × 0.0183 ÷ area (mm²). Keep under 3% of 12V (0.36V). Always go one size up from minimum for safety margin.
      System specification — shopping list
      Energy balance
      System wiring schematic Updates live with your system configuration
      Insulation
      Ventilation
      Heating
      Water System
      Weight & Payload
      Ply & Flooring
      Layout Planner
      Budget Tracker

      Insulation is the most argued-about topic in van building — and the most expensive to fix later. Enter your material choices and thickness for each zone. The tool calculates the R-value achieved, flags condensation risk, and tells you whether your van will be warm enough for UK winters.

      Insulation material
      Thinsulate
      λ = 0.033 W/mK
      No vapour barrier needed. Excellent for vans. Fills ribs naturally.
      PIR Board
      λ = 0.022 W/mK
      Best R-value per mm. Rigid — needs careful cutting. Combine with acoustic mat.
      Sheep Wool
      λ = 0.038 W/mK
      Natural, breathable. Handles moisture well. UK-grown option available.
      Spray Foam
      λ = 0.035 W/mK
      No air gaps. Bonds to metal. Hard to remove. Closed-cell only for vans.
      Rockwool
      λ = 0.036 W/mK
      Budget option. Absorbs moisture — use only with vapour barrier. Heavy.
      Kingspan TF70
      λ = 0.020 W/mK
      Best-in-class R-value. Premium cost. Used in high-spec professional builds.
      Van ribs reduce effective insulation by 15–30%. Filling ribs fully = lower bridging.
      Condensation risk — interior conditions
      Condensation risk gauge
      Dew pointSurface tempInterior temp
      Wall / ceiling R-value (effective)
      0.0m²K/W
      Floor R-value (effective)
      0.0m²K/W
      Dew point temperature
      °C
      R-value guide (UK)
      Minimum (budget build)R1.0 – R1.5
      Adequate (3-season use)R1.5 – R2.5
      Good (year-round UK)R2.5 – R4.0
      Excellent (winter trips)R4.0+
      Thermal bridging is the biggest insulation mistake in van builds. The steel ribs conduct heat directly through your insulation layer. Fill every rib cavity fully and use an acoustic/thermal mat (e.g. HushMat, FatMat) to break the metal-to-insulation contact.

      Good ventilation prevents condensation, removes CO₂, and makes your van liveable. The key is a roof fan that pulls air through the van combined with a low intake point — usually a cracked window or vent. Size your fan to achieve at least 15 air changes per hour at full speed.

      Van interior volume
      m
      m
      m
      Pre-filled from van selection if you selected your van in the Electrical module. Adjust for your specific roof height and bed/furniture layout.
      Popular roof fans
      MaxxAir 4000K
      400 CFM · 10 speeds · ~£280
      The go-to for UK van builds. Remote control, rain sensor.
      MaxxAir 7500K
      900 CFM · 10 speeds · ~£350
      For large Sprinter/Transit builds. Significant airflow.
      Dometic FreshLight 1100
      650 CFM · with LED light · ~£420
      Premium option with integrated lighting. Popular in high-spec builds.
      Fiamma Turbo Vent
      280 CFM · manual · ~£60
      Budget manual vent. No fan — wind-driven only. Fine for occasional use.
      Custom / other
      Enter CFM below
      CFM
      Interior volume
      0.0
      Air changes per hour (ACH)
      0ACH
      CO₂ risk (2 people, 8hr sleep)
      ACH guide
      Minimum acceptable< 10 ACH
      Adequate ventilation10–20 ACH
      Good (summer / cooking)20–40 ACH
      Excellent (hot climates)40+ ACH
      Fan placement: Position your roof fan over the rear third of the van. This draws fresh air in from the cab area and pushes stale air, cooking smells, and moisture out at the rear. Never fit a fan directly above the cooking area.

      A diesel heater is the most practical heating solution for UK van builds. Size it correctly — too small and you'll struggle in winter, too large and it cycles on/off inefficiently. The calculation uses your van's heat loss based on insulation, surface area, and the temperature difference you need to maintain.

      Heat loss inputs
      Typical values: T5/Trafic ~18m², Sprinter/Transit ~28m²
      R
      Popular diesel heaters
      VEVOR / generic
      2kW Diesel Air Heater
      0.8–2.0 kW · 12V
      ~£80–120
      VEVOR / generic
      5kW Diesel Air Heater
      1.0–5.0 kW · 12V
      ~£100–150
      Webasto
      Air Top 2000 STC
      0.8–2.0 kW · 12V
      ~£900–1200
      Eberspächer
      Airtronic D2
      0.6–2.2 kW · 12V
      ~£800–1100
      Eberspächer
      Airtronic D4
      1.0–4.0 kW · 12V
      ~£1000–1400
      Propex
      HS2000 (LPG)
      0.4–2.0 kW · LPG
      ~£350–500
      Heat loss at design conditions
      0W
      Required heater output
      0kW
      Selected heater
      VEVOR 2kW
      Running costs (est.)
      Chinese heater quality: Budget diesel heaters (Vevor, Webasto clone, etc.) work well when installed correctly. The key is proper fuel line routing, a quality fuel pump, and never running them at minimum output for extended periods (causes carbon build-up). Budget for a service kit.

      Size your water system for realistic daily use, not aspirational use. Most van dwellers use far less water than they expect — the constraint is tank size and weight, not desire. A 40–60L fresh tank is the sweet spot for most UK builds.

      Daily water usage
      System configuration
      #
      days
      %
      Daily water requirement
      0L/day
      Recommended fresh tank size
      0L
      Tank weight (full)
      0kg
      Water weighs 1kg per litre — include in payload calculation
      System components
      12V water pump (typical)Shurflo 2088 · ~£50
      Inline filter10" housing · ~£20
      Water heater (12V/gas)Truma AquaGo · ~£400
      Grey waste tankApprox 60–70% of fresh

      Payload is the most safety-critical and most-ignored calculation in van building. Exceeding your van's payload voids your insurance, makes the van illegal on UK roads, and affects handling. Check it before you build — not after.

      Van specs
      kg
      kg
      Select your van in the Electrical module to pre-fill typical GVWR and kerb weight values.
      Build components
      ComponentWeight (kg)Notes
      Available payload (stock)
      0kg
      GVWR minus kerb weight
      Build weight total
      0kg
      Remaining payload
      0kg
      Payload used
      UK law: Operating a vehicle above its GVWR is a criminal offence. It voids your insurance, risks prosecution, and endangers you and other road users. If you are close to the limit, consider upgrading to a higher GVWR variant, or fitting lighter components (LiFePO4 vs AGM, aluminium furniture vs MDF).

      Calculate how many ply sheets and how much flooring you need before you buy. Measure your van dimensions, factor in your insulation thickness, and the tool works out panel areas, sheet quantities, and waste.

      Interior dimensions (after insulation)
      m
      m
      m
      m
      %
      Total ply sheets required
      0sheets
      Floor area
      0.0
      Flooring + underlay
      Materials guide
      Ply lining (9mm birch)~£30–40/sheet
      Vinyl flooring~£8–15/m²
      LVT / click flooring~£15–30/m²
      Floor underlay (5mm)~£5/m²
      Acoustic mat (per m²)~£8–15/m²

      Drag furniture items from the palette onto the van footprint. The canvas is scaled to your van's dimensions. Double-click an item to remove it. Use this to test different layouts before cutting any wood.

      Furniture items
      Sleeping
      🛏Fixed bed (200×90)
      🛋Rock & roll (190×130)
      Kitchen
      🍳Kitchen unit (100×60)
      🚿Sink (50×50)
      Fridge (45×55)
      Storage & other
      📦Storage (80×50)
      🪑Seat/bench (50×50)
      🚽Toilet (40×40)
      👗Wardrobe (60×55)
      Drag items from the left panel onto the van. Double-click to remove. Blue = selected, use Rotate button to turn.

      Track your actual build spend against typical UK benchmark costs. Enter your figures — the tool keeps a running total and shows where you are vs an average build.

      Total build cost£0
      UK average build (similar spec)£0
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