The Darling 4+4 Van Build

The Darling Van came to life as an old Buick’s life began to fade…

As Nathaniel Darling’s old Buick sedan neared the end of its useful life, he knew his next vehicle purchase would prioritize protected space for his bikes. Nate is a devoted Wisconsin mountain biker who previously competed in races. Even hardy bikes that tear over rough terrain need to be kept dry and clean of grimy highway dirt and road salt. Nathaniel says, “I just wanted dry bikes.”

He considered a pickup truck to replace the Buick until a friend suggested a cargo van — price and gas mileage are similar (16 or 17 mph), and a van brought added versatility. Nate purchased a brand-new 2018 Ram ProMaster 136” wheelbase with swiveling seats.

Red powder-coated bed frame

Bed platform, looking toward rear doors of van

Table, kitchen, and cabinetry

Dometic fridge, accessed through a hinged countertop

Dometic fridge, accessed through the drawer

Bed platform and overhead cabinetry

The van accommodates either 2 removable passenger seats...

... or an adjustable, removable table

Pull-out bike stand for making repairs on the road

Build Requirements

Dedicated space for 4 bikes + 4 people
Van Life comforts: kitchen, tabletop, and seating for 2
A pull-out bike rack for making repairs on the go

Next came the build-out of the van. Nathaniel, then with his wife, Rachel, always placed priority on bike storage and seating for friends. They wanted space for 4 bikes and seats for 4 people, along with some cushy essentials like a refrigerator and lounging space for when Nate and Rachel traveled alone.

They started the van build with Open Road Upfitters in early 2020. Initially, Nate and Rachel intended to take on the interior build-out themselves. They hired ORU to do only “the scary stuff,” like cutting holes in the van's exterior steel for windows and a vent fan. Tony also constructed the bed frame (powder-coated in an eye-catching red that’s further accentuated by muted blue cabinetry) and his proprietary Roll’N Rack system for storing four bikes in a narrow space (just 48” wide) in the rear garage.

They took their partially-outfitted rig on a mountain biking trip to Arkansas and Colorado the first summer.

Later that year, Nate and Rachel purchased a house. DIY-ing house projects and a van was more than they cared to take on, so they asked ORU to upfit the rest of the interior in late 2020/early 2021.

For the final build-out, Tony installed a pull-out bike stand in the garage so Nate could make bike repairs on the road. He added roof-mounted brackets for a MoonShade detachable vehicle awning. (The detachable awning is a great choice for van travelers who wish to maintain stealth.)

Completing the build were a Dometic refrigerator, kitchen cabinetry and countertops, a row of custom-fitted upper cabinets, and bench seats for additional passengers. The removable bench passenger seats can be swapped out for a swiveling, adjustable-height table top.

Challenges

The relatively tight space presented challenges for the Darlings and for Tony. The 136” wheelbase is on the smaller side for vans ORU has built. The short length, combined with the 4-bike requirement, meant everyone had to find solutions and compromises on the layout — for example, the refrigerator, with its two access points. Initially designed so the Darlings could reach a cold beer while playing card games at the table, the pull-out refrigerator drawer also required secondary access from above through the flip-up countertop, necessary for when the bench seats are locked in place.

Outcome

Nathaniel and Rachel love the storage (there’s more than enough to hold their belongings and food), the workable space for cooking, playing cards, and hanging out, and the inherent ability to chase their love for riding. When it’s raining or snowing in one location, "we just look at the radar, see where it’s not raining, and go there.” Sometimes that means crossing state lines to chase dry trails — but with their camper van, that’s no issue.

During their first summer, 2021, with the fully-built van, Nathaniel and Rachel hit up Asheville, North Carolina, for a week. They spent weekends visiting Wisconsin's far-flung mountain bike trails, seemingly bespoke for people like Nathaniel and Rachel. They haven't gotten a hotel room once since ORU finished their van.

During winter 2021-22, they’ll spend their holiday break touring Arkansas, New Mexico, Arizona, California — and who-knows-where else. “We’ll ride everything we can, and then somehow get home.”