Sara’s BattleVan Build — 10 Years Later

When RECOIL OFFGRID recently resurfaced videos from nearly a decade ago documenting Sara’s original BattleVan build, it sparked a question: How has it actually held up?

Almost 140,000 miles later, the answer is simple — better than expected. (see the van inside today on our instagram page here)

Why Body-on-Frame Still Wins

From the start, Sara chose a body-on-frame platform over a unibody van like a Sprinter or Transit. Strength, durability, and long-term serviceability mattered more than interior headroom. Being able to stand upright inside wasn’t a priority — managing overall exterior height was.

As a photographer regularly working in cities, parking garage access was non-negotiable. A tall van might offer interior comfort, but it limits where you can go. The BattleVan needed to move seamlessly from remote desert roads to downtown parking structures without hesitation.

The 4WD Question

Yes, she considered four-wheel drive.

But with realistic use in mind — roughly 80% highway travel and 20% boondocking — the investment didn’t make sense. A 4WD conversion meant more upfront cost, more maintenance, more complexity. For a work rig designed to reliably cover long distances, simplicity won.

Lessons From Vans Past

The BattleVan’s layout wasn’t guesswork. It was shaped by years of trial and error.

First came a 1977 Dodge B-Body — complete with Cookie Monster blue shag carpeting floor to ceiling, a Molly Hatchet airbrush mural on the rear doors, and a cooler fridge wearing matching artwork.

Then came the 2003 Dodge Ram van, affectionately called the “Dodge Mahal.” It served faithfully across race tracks and job sites — until it stranded her in Minnesota with only hours to get back to Pennsylvania for a shoot. That moment made the decision clear: it was time to build something dependable.

Enter the 2017 GMC Savana

Sara ordered a brand-new 2017 GMC Savana cargo van — empty, windowed all around, and equipped with the 6.0L V8 (the real prize). The windows would later be blacked out, but having them meant enjoying the view while camping.

Plans were drafted and handed to David Adams of Clever Crow Fab. Ironically, Sara should have been more hands-on during the build, but a serious motorcycle accident — followed by four surgeries to save her right foot — kept her sidelined.

Built for Work First

Experience had already taught her what she didn’t need. No built-in shower. No elaborate plumbing system. She typically boondocks for 3–4 nights, then grabs a campground to enjoy real showers, laundry, and a pool while resupplying closer to town.

The entire design centered around a custom-ordered Truck Vault — secure, lockable storage for camera gear that doubles as the bed platform. An added bonus? It maintains temperatures roughly 30 degrees cooler than the van’s interior — critical for sensitive equipment.

A custom mattress from Mattress Insider tops it off. The rest of the cabinetry? Clever Crow craftsmanship.

A compact fridge has quietly done its job for ten years without complaint.

Power & Practicality

A Fiamma side awning provides shade when nature doesn’t. Zamp solar panels keep essentials powered, while shore power ensures batteries stay topped off during cloudy stretches.

Exterior lighting from Rigid Industries turns night into day when setting up in remote locations.

She upgraded to Dick Cepek wheels for looks but kept stock tire sizing — preserving highway mileage and handling. Form met function without sacrificing drivability.

Ten Years In

There’s been minimal wear. A small leak around the ceiling vent fan was sealed. The LED ceiling lights likely suffered minor water damage and need replacement. Otherwise? It’s held up impressively.

After nearly a decade and 140,000 miles, Sara wouldn’t change a thing.

The BattleVan wasn’t built to chase trends. It was built to work — and that’s exactly what it’s done.  For more Van content from sara Follow @Van_Solo_ on Instagram