We Built The ULTIMATE Offroad Passenger Van

If you know anything about Off Highway Van, you know that passenger vans are not our typical van conversion. Though we specialize in performance offroad camper vans, we will take on a custom project from time to time and we jumped at the opportunity to outfit the Lotko Family Lodge in Breckenridge, Colorado with a fully-custom ski shuttle.

Building The Ultimate Offroad Passenger Van

This build was never about creating the average ho-hum passenger van. It started as a challenge to our engineering team to create a purpose built transport vehicle that was not only reliable, but safe and comfortable, even the most demanding mountain conditions: and they delivered.

This van was engineered to perform throgh snow, ice, and elevation all while providing a premium experience for every passenger.

Performance-Based Modifications

It wouldn't be an Off Highway Van if performance was not top-of-mind throughout the build.

We outfitted this van with 32" BF Goodrich™ K03 A/T tires wrapped around 17" Reika™ Rambler offroad wheels to provide a bulletproof foundation to the van build that provides traction and grip on snow and ice. In case of a flat, we also include a matching spare tire mounted to the rear door using a Dark Star Offroad Tire Carrier.

Evictus 2.65" Prerunner Suspension Kit

To keep the van stable even in the most challenging terrain, we've outfitted this build with the Evictus™ 2.65" Suspension Kit to improve ride quality as well as providing consistent damping and reduced body roll which is critical for both passenger comfort and performance on rough access roads.

Warn Recovery Winch + Factor 55 UltraHook

If things get hairy on the trail, we've outfitted this passenger van with a front-bumper integrated Warn™ recovery winch so you can keep moving even if things don't go completely to plan. We also include the Factor 55 UltraHook winch end for improved safety and performance when winch tension is applied.

ARB Onboard Air Compressor

An ARB™ onboard air compressor allows for quick tire pressure adjustments on the fly whether you need to air down for increased offroad traction, or quickly inflate for on-road performance and highway comfort.

Offroad Skid Plate Kit

Though Sprinter vans have solid clearance (10.5" differential clearance with upgraded suspension), this van's use case as an offroad shuttle called for extra undercarriage protection. We outfitted the Lotko Lodge passenger van with a full offroad skid plate kit that protects the engine, transmission, and rear differential from any obstacles they may find on the trails.

Dark Star Offroad Limited Slip Differential

One of the most important upgrades you can make to your offroad van is a limited slip differential from Dark Star Offroad™. This takes the already intelligent AWD Mercedes™ Sprinter system and improves on it.

This differential automatically transfers torque to the wheels with the most traction increasing control on slippery grades and challenging terrain. It also helps you avoid the dreaded "1-wheel AWD" that vans without a differential can get trapped in when conditions get slippery or wheels get buried.

S&B 45-Gallon Extended Range Fuel Tank

No one wants to be running their shuttle rig back and forth to the gas station constantly. That's why we outfitted this van with an S&B™ 45-gallon extended range fuel tank. This will allow the Lodge to complete multiple day trips without having to head to town for a refuel in between.

Dark Star Offroad Series A Roof Rack

Though this van is outfitted with a massive ski box (discussed later) it also includes the Dark Star Offroad™ Series A roof rack, which not only holds the solar energy system and dual Nomadic Innovations™ A/C units, it is also perfect for extra gear storage, adding storage boxes, and more!

Experience-Based Modifications

Dark Star Offroad Steps

Ease of access is crucial, especially for a passenger van. That's why we've outfitted every enterance of this custom passenger van with Dark Star Offroad™ driver, passenger, and rear steps.

Avatar Offroad Ski Box

It wouldn't be a shuttle vehicle if it didn't have storage for everyone's gear. We've added an enormous Avatar Offroad™ ski box to the back of this passenger van that can hold up to 6 pairs of skis (poles included). This allows the interior of the van to stay clear of clutter and snowy, wet gear.

Dark Star Offroad Side Ladder

When you need to access the extra gear on this van's roof, you don't have to worry about stability with the Dark Star Offroad™ side ladder. This ladder makes accessing the roof rack, and any gear that may be stored on it, a breeze.

Roof Rack Flood Lights

The Dark Star Offroad™ Series A roof rack comes standard with global lighting that illuminates the area both on the rack and around the van: perfect for those early morning laps or last chair days when you don't want to bust out the headlamp.

Creating a Luxury Passenger Van Interior

We've talked a lot about performance mods, but performance isn't all Off Highway Van is known for.

We're also known for our premium, fully-customizable van interiors that truly allow you to create a 1 of 1 van specific to you. The Lotko Lodge took full advantage of this customization.

Seating For 11

No, that's not a typo. This custom passenger van was outfitted with custom-upholstered front seats as well as 9 additional captain's chairs to allow the lodge to carry up to 10 people (plus a driver) comfortably at a time! All of these seats are securely mounted for stability in rough terrain and are all custom upholstered with premium Taupe UltraLeather™ for superior comfort, style, and durability.

Dual-Layer Thinsulate Insulation

Just like our Off Highway Van models, this custom passenger van was outfitted with dual-layer Thinsulate™ sound-deadening insulation for both temperature management and road noise reduction: both functions are extremely important for guest comfort.

Series A Aluminum Overhead Cabinetry

Overhead, you'll see 120" of our Series A aluminum cabinetry which adds lightweight, durable storage for guest equipment and adventure supplies. The Lotko Lodge team chose a Super Rootbeer coating from Prismatic Powders™ along with walnut cabinet faces to give the interior of their van the premium feel they were searching for for their guests.

Nomadic Innovations Climate Control

With passenger comfort being top of mind, climate control was a major focus for the design of this van. That's why we optioned this build with dual Nomadic Innovations A/C systems to ensure consistent temperature regulation whether its 70 or -20 outside.

Premium Sound System From JL Audio

What good would a shuttle van be without the ability to crank up the energy? We've taken this build up a notch with a premium JL Audio system including upgraded door speakers, and amp, and added rear door surround sound to keep your crew queued up to their favorite tracks up all the way to the destination. These speakers provide powerful, but balanced, sound throughout the cabin.

Lonseal Marine-Grade Flooring

The flooring of this passenger van is marine-grade. This means it's not only durable, it's slip-resistant, mold-resistant, and waterproof: all things you need in a ski shuttle. This material is also extremely easy to clean and wipe down making for easy details between guests.

Custom Fit + Finishes

It wouldn't be an Off Highway Van if our team didn't have a bit of fun with the fit and finish of this van's interior. Our team not only custom designed the graphics package for the exterior, they also brought the Lotko Lodge branding to the interior of the van as a bit of an easter egg and a nod to the overall continuity of the build.

This Isn't A Passenger Van, It's an Off Highway Van

Just because the interior may look a little different, doesn't mean it's not an Off Highway Van. Every van we engineer is built and tested in-house ensuring your dream van is road-ready from day 1.

This build is still covered by a 5-year bumper-to-bumper warranty and a lifetime craftsmanship warranty ensuring both long-term durability and support. From rugged offroad modifications to refined passenger comfort, this isn't just another passenger van, it's an Off Highway Van.

Ready to start your own Off Highway Van build? Get in touch with one of our van design experts today!