Ford Transit High Roof Conversion: Complete Build Guide

Why the Ford Transit?

The Ford Transit 250 High Roof has become the van of choice for full-time van lifers, and for good reason. At 6'3" of interior standing height, it's the tallest option in its class. Ford's dealer and parts network means repairs are easy anywhere in the US. And the 3.5L EcoBoost engine provides solid power for mountain passes.

The Build Plan

Our build took 90 days working weekends and some weekday evenings. Total cost: $18,500 (not including the van itself). Here's how it broke down by phase.

Phase 1: Insulation & Vapor Barrier (Week 1-2, $800)

We used Havelock wool insulation throughout — it's natural, moisture-regulating, and doesn't off-gas like spray foam. The walls got 2" of wool held in place with 3M adhesive. The ceiling got 3" for extra heat retention. We added Reflectix on all windows we planned to cover and used a layer of Tyvek as our vapor barrier.

Phase 2: Electrical System (Week 3-4, $3,200)

This is where most builds either overspend or underspend. Our system: 400Ah lithium batteries (Battle Born), 2000W Victron inverter, 400W of rooftop solar (2x 200W Renogy panels), 30A shore power hookup, and a Victron MPPT charge controller. This runs a mini-fridge, laptop charging, LED lights, a MaxxFan, and occasionally a small induction cooktop.

Phase 3: Walls & Ceiling (Week 4-5, $1,500)

We went with tongue-and-groove pine planks for the ceiling (warm, lightweight) and birch plywood for the walls (durable, clean look). Everything was stained with a natural oil finish.

Phase 4: Cabinetry & Bed (Week 5-8, $4,000)

Built a full-width queen bed platform at the rear with pull-out storage drawers underneath. A two-burner propane cooktop with a fold-up counter extension, and overhead storage cabinets the full length of both sides. All built from birch plywood with soft-close hinges.

Phase 5: Plumbing (Week 8-9, $2,000)

20-gallon fresh water tank and 15-gallon gray water tank, both mounted under the van. A Shurflo water pump feeds a small bar sink. We added an on-demand propane water heater for an outdoor shower setup.

Phase 6: Finishing Touches (Week 9-12, $7,000)

MaxxFan Deluxe ceiling vent ($350), Dometic 50L 12V fridge ($900), custom cushions ($800), LED lighting throughout ($200), USB outlets and switches ($150), window coverings ($300), exterior ladder and roof rack ($600), and countless small items that add up fast.

What We'd Do Differently

Spend more on the mattress (we upgraded after 3 months). Run more electrical outlets than you think you need. And install the MaxxFan before the ceiling panels — it's much easier.