Exterior UPgrades
Exterior stuff - Make your van Mean!
Exterior mods are where your van starts to show its personality. Racks, lights, bumpers, windows, tires, and suspension aren’t just functional—they’re how you make your van yours. They change the way it feels to drive, the way it’s seen on the road, and the way it meets the challenges of the places you take it.
These upgrades add versatility and durability, giving you more options for carrying gear, protecting your investment, and handling rough terrain. But they also bring a certain presence—a look that says your van is ready for anything. This is the fun part, the nice-to-have that can turn a good build into something unforgettable.
Roof Racks
A roof rack is one of the most functional—and visually defining—exterior upgrades you can put on a van. Beyond looking sharp, a good rack expands what your van can carry and how you can use your roof space. From solar panels to gear boxes, kayaks to decking for a sunset hangout, the roof rack turns wasted space into a hard-working platform.
Modern high-end racks, like those from Flatline Van Co, Orion, Slimlines, and Owl Vans (LINKS!), are laser-cut for precision and designed to follow the exact contour of your roofline. This gives them a clean, factory-level fit that’s as aerodynamic as it is stylish. Many are modular, so you can add or reconfigure panels, crossbars, and mounting points as your needs change. The result is a streamlined, versatile system that looks as good empty as it does fully loaded.
For a simpler, more cost-effective approach, crossbar systems from Yakima, Thule, or even off-brand Amazon options get the job done. They’re perfect for basic mounting—think a cargo box for extra storage or a solar panel setup—without committing to a full platform rack.
Older trade vans often relied on rain gutter mounts, but most modern vans now use factory in-laid bolt mounting systems. This change has opened up more precise and secure attachment options, reduced wind noise, and made installation cleaner and easier. DIY vans has cross bars that attach to each of the major vans if you’d rather go for a few cross supports than a full rack (link).
A well-chosen rack blends form and function—whether you’re going all-in with a contoured modular platform or keeping it minimal with a couple of crossbars.
Awnings
An awning is one of those upgrades you don’t truly appreciate until you use it—then it’s hard to imagine life without one. It instantly expands your living space, creating shade on hot days, shelter from rain, and a comfortable spot to cook, relax, or gear up before hitting the trail.
Modern awnings from brands like Fiamma, Thule, and ARB are designed for quick deployment, smooth operation, and durable performance in all kinds of conditions. Many integrate directly into roof rack systems, keeping them secure and out of the way when stowed. Others mount directly to the van’s factory in-laid bolt points, which keeps installation clean and minimizes the need for drilling. Here at CAV we install Fiamma products (check out this blog for more info).
You’ll find two main styles:
Manual roll-out awnings – lightweight, cost-effective, and quick to set up.
Powered awnings – extend or retract with the push of a button, ideal for frequent use or solo travelers.
For budget-friendly setups, smaller batwing or canopy-style awnings offer a lot of shade for their size and can be mounted to basic crossbars. This blog gives a good breakdown of the options for each van.
An awning doesn’t just make your campsite more comfortable—it changes the way you use your van. Whether you’re lingering over morning coffee in the rain or cooling off after a summer ride, it’s a simple piece of kit that makes outdoor living more inviting.
Windows
Few upgrades influence both the look of your van’s exterior and the quality of your interior experience as much as windows. They frame your views, bring in natural light, improve ventilation, and give your build a more open, inviting feel. From the outside, they can make a van look sleek and purpose-built—or mismatched and dated—depending on the choices you make.
We recommend avoiding the cheapest options. Saving a little up front often leads to headaches later—whether it’s leaks, poor insulation, or simply not being happy with how they function or look. Investing in high-quality windows will pay off in performance, durability, and satisfaction over the life of your van.
Some of our trusted sources include:
Van Windows Direct (link) – broad selection, good availability.
Campervan HQ (link)– carries multiple brands and specialized models.
Tern Overland (link) – premium windows with excellent insulation and airflow control.
CR Laurence (link)– industry standard in many professional builds.
AMA (link) – well-regarded for quality and fit in modern van conversions.
Whether you’re adding a single vented window near your bed or installing a panoramic row along the side, choose windows that complement your build’s style, meet your climate needs, and stand up to the miles ahead.
We’re always happy to help out with window installs, but if you plan to tackle the job yourself here are a few resources to make sure you get it right the first time:
CATuned
Flatline Van CO
Owl
Aluminess
Bumpers, Lights & Winches
Upgrading bumpers and adding auxiliary lighting changes both the look and the capability of your van. A well-designed bumper offers protection from impacts, a mounting platform for lights or a winch, and a more rugged, adventure-ready presence on the road. Pair that with strategically placed lights, and you’re not only safer after dark—you’re more prepared for off-road travel, remote campsites, and recovery situations.
Brands like CATuned, Flatline Van Co, Owl Vans, and Aluminess (links) build bumpers that are engineered for strength without adding unnecessary weight. Many designs integrate clean mounting points for LED light bars, spot lights, or driving lights, giving you targeted illumination for trail driving or nighttime setup.
If you spend time off-road or in remote areas, adding a winch can be a smart insurance policy. Integrated winch mounts keep the installation tidy, while still giving you the pulling power to self-recover—or help someone else—when the trail gets tricky. Warn winches (link) are somewhat of an industry standard (and they integrate with a lot of aftermarket bumpers), but Rhino Field Kit (link) gives an option for a cheaper, portable option that hopefully you never need to use.
Done right, bumpers, lights, and winches work together: protection, visibility, and recovery all in one package. And they make your van look like it means business, whether you’re rolling into a trailhead or driving through town.
External Gear Storage
External storage is all about freeing up space inside your van while keeping your gear protected, secure, and ready to grab when you need it. Whether it’s a cargo box for camp chairs and cooking gear, a bike rack for weekend rides, or a ski box for winter trips, sturdy mounting and weatherproofing are key.
The best systems offer weather protection to keep your gear dry, theft resistance to keep it safe, and solid mounting so it stays put on rough roads. External storage is also perfect for muddy or wet items—keeping them outside the living space means your van stays cleaner and drier inside.
Brands like Flatline Van Co, Flarespace, Owl Vans, and Aluminess (links) offer a range of solutions, from side-mounted storage boxes and rear swing-out carriers to roof-mounted cargo systems. Many can also integrate specialty mounts for boats, bikes, skis, or boards, so your adventure gear travels safely and securely.
With the right setup, you can carry more, worry less, and keep the inside of your van feeling open and livable—no matter how much gear the trip calls for.
Side Steps:
Side steps make getting in and out of your van easier, especially for passengers, kids, or anyone hauling gear. They also protect your rocker panels from road debris and give the van a more finished, adventure-ready look.
Fit and style vary depending on the platform: **I’m not sure if the below is true??????? we need to double check
Transit – Tallest step-in height of the three, so side steps make a big difference in daily comfort. Wide, flat designs work best here for stable footing.
Sprinter – Already has a slightly lower step-in than the Transit, but benefits from steps for added ease and a cleaner visual break along the body.
ProMaster – Lowest step-in height overall, so steps are often chosen more for style and rocker protection than necessity.
Brands like Flatline Van Co, Flarespace, Owl Vans, and Aluminess offer steps tailored to each van model, from low-profile designs that blend seamlessly with the body lines to heavy-duty, off-road-ready options with extra grip and durability.
Whether you choose them for function, style, or both, side steps are one of those small upgrades that you and your passengers will appreciate every time you open the door.
Wheels, Tires & Suspension
Wheels and tires influence everything from ride comfort to traction, and suspension upgrades can take your van from a stock people-mover to a road-trip-ready adventure rig. The right combination improves handling, expands terrain capability, and elevates the van’s stance for a more confident look.
Transit – Stock wheel wells are generous but watch offset to avoid rubbing when upsizing. Common upgrades include all-terrain tires in the 30–32” range with modest suspension lifts.
Sprinter – Popular with overlanders for its ground clearance and 4x4 options. 17” wheels are standard for many builds, with tire upgrades to all-terrain or all-season for versatility.
ProMaster – Front-wheel drive and lower ground clearance mean tire sizing is a little more limited, but ride comfort is high. Many owners choose light all-terrains or aggressive all-seasons to match their travel needs.
All-Season & All-Terrain Tire Options
All-season – Best for mixed highway driving with occasional mild weather challenges. Smooth, quiet ride.
All-terrain – More grip on dirt, gravel, and snow, but slightly louder on pavement.
Wheel Sizing
Exact fit depends on van model and suspension setup, but:
16–17” wheels are the standard upgrade size.
Larger wheels/tires require suspension modifications to prevent rubbing.
Popular Suspension Upgrades
Upgraded shocks & struts – improves handling and comfort.
Lift kits – adds clearance for larger tires and rougher terrain.
Helper springs or airbags – stabilizes the ride under heavy load.
**Mondo mud guards (link) and other kits that allow you to fit bigger wheel/tire combos
We use 5280 Sprinter Service (link) and Tourig (link) for wheel, tire, and suspension work on our adventure vans, offering everything from bolt-on upgrades to fully tuned systems for long-distance travel and off-road performance.
Starlink
MIni VS Standard comparison
Veritas van mounts, van interior mounts for router/power supply, amazon roof mounts, magnets and suction cups\