We turned a Ram ProMaster 3500 RV into a true off-road adventure van — an Off Highway Vans 3-inch lift on BFGoodrich KO2s, Baja Designs LP9 Pro driving lights, and a full round of in-house fabrication: a custom front hitch, a spare-tire carrier with off-road light mounts, a skid plate for the under-van generator, and even rear couch headrests. A top-to-bottom build that makes a camper genuinely backcountry-capable.
This ProMaster 3500 came through Juggernaut USA in Wheat Ridge (Denver), CO because the owner wanted her camper to go where the pavement ends. We lifted it, geared it up with lighting and gear mounts, and fabricated the pieces that do not exist off the shelf — the front hitch, the spare carrier, and a skid plate to protect the low-hanging generator. This is the full expression of what we do: parts and custom fab, together, on one van.
| Component | Part |
|---|---|
| Vehicle | Ram ProMaster 3500 RV |
| Lift / tires | Off Highway Vans 3-inch lift, BFGoodrich KO2 |
| Lighting | LED headlight bulbs + Baja Designs LP9 Pro driving lights |
| Custom fab | Front hitch, spare-tire carrier with light mounts, under-van generator skid plate |
| Camp | Ladder + jerry can mount, rear couch headrests |
Lift, tires, and long-range lighting
The 3-inch lift and KO2 all-terrains give the ProMaster real ground clearance and traction for dirt and snow, and the Baja Designs LP9 Pro lights (on top of upgraded LED headlights) let it actually see down a dark forest road. That is the foundation — the rest is what makes it livable and self-sufficient out there.
The custom fabrication
Off-the-shelf parts only go so far on a build like this, so we fabricated the rest in-house: a custom front hitch, a spare-tire carrier with off-road light mounts, and a skid plate to protect the generator that hangs under the van. We even built headrests into the rear couch that converts to a bed. This is the kind of one-off metalwork that separates a real overland conversion from a lift-and-tires job.
Protecting the underside
A generator hanging under a van is exactly the kind of expensive, low-slung component that a rock finds first — which is why we built it a skid plate. We also make aluminum underbody armor for the ProMaster in-house: our ProMaster generator skid plate and front engine, transmission & cat skid plate protect the vulnerable hardware underneath.
Common questions on this build
Can you make a camper van off-road capable?
Yes — lift, tires, lighting, armor, and custom gear mounts turn a road-going camper into one that can reach remote trailheads and camp. We build the parts that do not exist off the shelf.
Do you fabricate custom parts for vans?
Yes — front hitches, spare carriers, skid plates, and mounts, all designed and welded in-house for your specific van.
Can you protect my van's generator or battery?
Yes — we build skid plates for under-van generators and battery packs, and make aluminum ProMaster armor in-house.
Book the same work
We build and fabricate overland vans in-house at our Wheat Ridge shop north of Denver — lifts, lighting, armor, and custom metalwork. We serve Denver, Wheat Ridge, Golden, Arvada, Lakewood, and the Front Range. Call (970) 341-4221 to talk through your build, or see our install services and custom fabrication. More from the bay: our Winnebago Travato ProMaster build and AWD Ford Transit camper build.
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