CAD

All Pro Pro Van Kits first begin with a computer design of the final project. With over 800 individial components in a typical van build, computer aided design (CAD) dramatically reduces the time and therefore the cost of every project. Without CAD, the design process is prone to costly errors. On average, Pro Van Kits can complete a van build in approximately 2 weeks instead of the typical 2 months. That means at least a $15,000 savings per build. To speed the deign process, Pro Van Kits generates its own CAD models for almost every part used in our vans: sinks, faucets, electronics, water tanks, etc. Although our CAD library of over 1000 parts required asubstantial investment in time on our part, it has long term benefits of speeding all subsequent van builds. It also reduces errors in van builds because we are 100% sure that everything fits in the proper place. The majority of the cost of a van conversion is not the components in the van, but the labor to install it. We've found the ration is 75% labor and 25% components. Of the 25% we source internatiolnally to reduce even that cost

CNC

The next step in a automated manufacturing system is to convert a CAD file into a physical component. It's possible to generate detailed dimensional drawings and make parts by hand, but with Computer Numerical Control (CNC) components can be fabricated in just minutes. From a single piece of 4' x 8' sheet of plywood we create all the parts necessary for a cabinet, galley or bed. The precision automated process allows us to design our vans to speed, simplify, and lower the cost of every project. A cabinet with a dozen parts can be machined, assembled, and installed in little over an hour at a fraction of the cost.

ENGINEERING

Pro Van Kits custom engineers all it's van builds. We love to break from tradition and employ innovative design techniques, van layouts, and components. We evalute all parts of parts of a design constantly looking for new ways to reduce cost, complexity, and the labor required in a van build.

With our mechnical and product design expertise we have custom designed some of the major components used in a van build such as hot water heaters, ventillation equipment, and flooring systems. For example, our ehaust system replace two Maxair fans at a cost savings of $500 and 80 Watts of power.

ASSEMBLY

Because Pro Van Kits uses CAD and CNC we build our van in "kits". Prior to installing any large components in our builds we know that they will fit. We design to an accuracy of 1/16" of an inch Our ceilings. for example, are created from three 4' x 8' plywood panels with all the assembly features milled into the panels. Beside costing less than $200 in material costs, we can install a complete van ceilng in as little as 2 hours. We can often install an insulated floor in under a half hour. The total cost of a van build is mostly driven by labor hours in a build. For our vans total material costs is less than $5,000 and labor approximately $10,000. The hidden cost of any DYI build is the builder's labor cost. On a 3 month do-it-yourself build labor costs typically exceed $20,000.