How to Retrofit a Propane Heater for a Van Conversion: A Comprehensive DIY Guide

Retrofitting a propane heater for a van conversion is a crucial step in creating a comfortable and efficient living space on the road. This comprehensive guide will walk you through the process, providing advanced hands-on details and technical specifications to ensure a successful installation.

Selecting the Right Propane Heater

When choosing a propane heater for your van conversion, it’s essential to consider factors such as the size of your van, the desired heating output, and safety features. A popular option is the ventless propane heater, which can be installed without the need for external venting. These heaters are designed for indoor use and typically feature safety mechanisms like an oxygen depletion sensor and a tip-over shut-off.

Some key specifications to look for in a propane heater for van conversion include:

BTU Rating: The heater’s BTU (British Thermal Unit) rating should be appropriate for the size of your van. As a general rule, you’ll need around 30-40 BTU per square foot of living space.
Dimensions: Ensure the heater’s dimensions fit the available space in your van, allowing for proper installation and airflow.
Fuel Type: Verify that the heater is designed to run on propane, as this is the most common fuel source for van conversions.
Safety Features: Look for heaters with features like an oxygen depletion sensor, a tip-over shut-off, and a built-in thermostat for temperature control.

Placing the Propane Tank

The propane tank for your van conversion should be installed in a sealed locker with a vent to the outside. This is crucial to prevent any potential gas leaks from accumulating inside the van and to allow fresh air to enter the locker. The locker should be large enough to accommodate the tank and any necessary valves or regulators.

When selecting a propane tank, consider the following:

Tank Size: Typically, a 5-20 gallon propane tank is suitable for most van conversions, depending on the size of your van and your heating needs.
Tank Material: Aluminum or steel propane tanks are both common choices, with aluminum being lighter and more corrosion-resistant.
Tank Placement: The tank should be placed in a secure location, such as a dedicated storage compartment or a custom-built locker, to prevent damage or movement during travel.

Propane Tank Ventilation

Proper ventilation of the propane tank locker is crucial to ensure the safety of your van conversion. The locker should be vented to the outside, allowing any propane that may escape to exit the van. This can be achieved by installing a vent near the bottom of the locker, which will allow fresh air to enter, and a vent near the top, which will allow any propane vapors to escape.

When designing the ventilation system, consider the following:

Vent Size: The vents should be sized appropriately for the size of the propane tank locker, typically ranging from 1-2 inches in diameter.
Vent Placement: The bottom vent should be positioned near the floor of the locker, while the top vent should be placed near the ceiling to allow for proper air circulation and propane vapor removal.
Vent Material: Use corrosion-resistant materials, such as stainless steel or aluminum, for the vents to ensure long-term durability.

Propane Line Installation

The propane line that runs from the tank to the heater should be installed using copper or stainless steel tubing, as these materials are resistant to corrosion and can handle the pressure of the propane. The line should be secured along the frame of the van using clamps or straps, and should be insulated to prevent freezing in cold weather.

When installing the propane line, keep the following in mind:

Tubing Size: The propane line should be 1/2″ or 3/4″ in diameter, depending on the size of your heater and the length of the run.
Tubing Material: Copper or stainless steel tubing is recommended for its durability and resistance to corrosion.
Insulation: Insulate the propane line to prevent freezing and maintain consistent fuel flow, especially in cold climates.
Routing: Secure the propane line along the van’s frame using clamps or straps, ensuring it is out of the way and protected from potential damage.

Heater Installation

The propane heater should be installed in a location that is easily accessible and allows for proper heat distribution within the van. The heater should be mounted securely to the van’s frame or wall, using screws or bolts, and should be level and stable to prevent any potential tip-overs.

When installing the heater, consider the following:

Mounting Location: Choose a location that is easily accessible for operation and maintenance, and ensures even heat distribution throughout the van.
Mounting Hardware: Use appropriate screws or bolts to securely attach the heater to the van’s frame or wall, ensuring a stable and secure installation.
Clearance: Maintain the manufacturer’s recommended clearances around the heater to allow for proper airflow and prevent fire hazards.
Accessibility: Ensure the heater controls and any necessary vents or exhaust are easily accessible for operation and maintenance.

Carbon Monoxide Detector

To ensure the safety of your van conversion, it is essential to install a carbon monoxide (CO) detector near the propane heater. This will provide an early warning in case of any potential carbon monoxide leaks from the heater, allowing you to take immediate action.

When selecting a carbon monoxide detector, look for the following features:

UL Listing: Choose a CO detector that is UL-listed, ensuring it meets safety standards.
Alarm Volume: The detector should have a loud, audible alarm to alert you in the event of a CO leak.
Battery Life: Opt for a detector with a long-lasting battery to ensure continuous monitoring.

Testing and Maintenance

After the installation of the propane heater system, it is crucial to test the entire system for any leaks using a propane leak detector solution. Regularly inspect the system for signs of wear or damage, and ensure that the propane tank is properly filled and maintained.

During the testing and maintenance process, consider the following:

Leak Testing: Use a propane leak detector solution to thoroughly check all connections and fittings for any potential leaks.
Visual Inspection: Regularly inspect the propane line, tank locker, and heater for any signs of wear, damage, or corrosion.
Propane Tank Maintenance: Ensure the propane tank is properly filled and that the regulator and valves are functioning correctly.
Heater Maintenance: Follow the manufacturer’s recommendations for cleaning, servicing, and maintaining the propane heater.

By following this comprehensive guide, you can successfully retrofit a propane heater for your van conversion, creating a comfortable and efficient living space on the road. Remember to prioritize safety, attention to detail, and regular maintenance to ensure the long-term reliability and performance of your propane heating system.