Common Electrical Mistakes in DIY camper Van Builds (and How to Avoid Them)

Before

After

At Adventure Life Vans, we see a lot of DIY electrical setups in van builds—some done well, and others that raise major safety concerns. Whether you're tackling a full electrical install yourself or just maintaining your system, there are a few common mistakes we see over and over again. Let’s break them down so you can build (and maintain) a safe and reliable electrical system for your adventure rig.

1. Mixing Automotive and Residential Components

One of the biggest issues we come across is people blending automotive and residential electrical components. It might seem harmless—after all, a sub-panel is a sub-panel, right? Not exactly.

Residential electrical components are designed to be stationary—mounted to the wall of a house that doesn’t move. Vans, on the other hand, are constantly bouncing, vibrating, and flexing on the road. This movement can lead to loose connections, broken wires, and even electrical fires if the wrong components are used.

What to do instead: Stick with automotive or marine-grade electrical components that are designed for mobile applications.

2. Using Solid Core Wire Instead of Stranded Wire

Another common mistake is using solid core wire, like the 12/3 wire you can grab at Home Depot. While this is perfectly fine for wiring a house, it’s a disaster waiting to happen in a van.

Why? Solid core wire is rigid and prone to breaking over time due to the constant movement of a vehicle. Every bump in the road puts stress on the wire, and eventually, it can snap—leading to electrical failures or worse.

What to do instead: Always use marine-grade stranded wire for your van build. Stranded wire is flexible and designed to withstand the vibrations and movement of a vehicle.

3. Using Wire Nuts Instead of Proper Crimps

Wire nuts are great for home electrical work, but they should never be used in a van. Like solid core wire, wire nuts aren’t meant to handle movement and vibrations. Over time, they can loosen and cause unreliable connections or even shorts in your system.

What to do instead: Use proper crimp connections with heat shrink tubing. This creates a secure, durable connection that won’t come loose as your van moves.

4. Neglecting Regular Maintenance Checks

Even if your electrical system is professionally installed, it still needs regular maintenance. Connections can loosen over time, and if you’re not checking for them, you might not notice a problem until something stops working—or worse, overheats.

What to do instead: Either:

• Hire a professional to perform periodic maintenance checks, or

• Do it yourself by inspecting connections, tightening terminals, and looking for signs of wear or overheating.

Final Thoughts

Your van’s electrical system is the backbone of your build—powering everything from lights and appliances to charging your devices. Taking shortcuts with the wrong materials might save time and money upfront, but it can lead to big (and costly) problems down the road.

At Adventure Life Vans, we believe in building systems that last. If you need help designing, installing, or maintaining your van’s electrical system, reach out—we’re here to make sure your adventure rig is safe, reliable, and ready for the road!