Sprinter Van Conversion Hydronic Hot Water System Install

Sprinter Adventure Van Build Series Episode 14: In this installment of the Sprinter #VanLife Build Series we are tackling the first major install portion of our Hydronic Water Heating System. This system will allow us to heat and store hot water in our van using 3 distinct redundant methods a necessary luxury with a wife and dogs!

** NOTE: We are not professional builders and this video is for entertainment purposes only. We base our decisions on our own research, decades of knowledge gained from building other things and always with an engineering mindset. You should always follow the manufacturers instructions, do you own research and ONLY attempt projects like this at your OWN risk.

**NOTE: Some of the links below are affiliate links and we receive a small commission for purchases products through those end points. We will never recommend a product we don't stand behind and use ourselves. Everything listed below we used for our own build and weekly, if not daily, for our other ventures. Thank you for your support!

Tools Used

Supplies Used

For shortening the Espar Pump Cable:

Video & Sound Equipment Used to Make this Video:

Video Contents & Chapter Markers:
0:00 - Wish You Had Hydronic Music Video (Intro)
1:17 - Moonraker Design Co
1:37 - Hydronics
2:25 - Isotemp Water Heater Install
8:19 - Espar D5e Install
13:44 - Overflow Tank Fabrication
15:14 - Coolant Hose Routing & Install
24:28 - Espar D5 Intake & Exhaust
26:00 - Wiring & Wrapping Up
31:30 - Moonraker Recap
32:52 - Outro

Music from Uppbeat (free for Creators!):
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License code: 88WKF7YT5EVWR3GI
License code: HF8PBCSNDGN7BJ2H
License code: RNGQIDJQDGYYOQLO
License code: XK9LRTHMIPSH3D1A

[ndraju]

Todd your attention to detail is way over the top! In a good way lol. Would love to meet you somewhere along the way. I am in the process of building out a 2024 AWD myself.

[masiquraishi]

My dad has been building a sprinter van for a while but seems to make no progress unless I am helping and always watches videos and shares them with me. I feel like I have seen most of the folks who make videos about van conversions but you my friend are a cut above the rest really glad I stumbled on this video and now your channel!

[chosmer]

George Lucas and Alanis Morissette are shaking in their boots with the filmmaking and singing going on here. Excellent mix of humor and top notch MacGyver Van building going on here. I am blown away by some of the tools you have, you take "having the right tool for the job" to another level. This guy whips out metal brackets to mount hoses that look like they should be on Falcon nine rocket. Please don't stop making videos, these are awesome!

[meestahwah]

I LOVE LOVE LOVE all the custom brackets, chafe guard, and wiring loom work. I installed a similar system on my sailboat and went to a similar level of detail.

[ivant.]

You are using so fancy tools! Unheard of tools. And those custom made brackets?/ How did you do all that? Are you using some fancy 3D printer? That's crazy work! I read your disclaimer that this is not professional. If that is not professional, I don't know what else would be. I have never seen something like that!

[GlennInLaguna]

4:14 I think you have a lot of experience with rivnuts. I'd like to ask your opinion about mounting Unistrut on my vans walls. I am building out a work van and was wanting to put Unistrut on the walls so that I can mount modular cabinets to it. Mounting like FeatherBuilt does, you can look up their basic Foundations kit and see how they mount it on the walls, I want to do mine like that. Do you know what size rivnut would be used to mount Unistrut to my van's walls (I plan to buy my Unistrut from McMaster)? I see a lot of opinions about Rivnut's verses Plus-Nuts or even using a combination of the two. But it seems most guys like yourself and others who have a higher level of attention to detail (like Project of Science), use mostly rivnuts. And with the proper tools maybe rivnuts are best if you install them correctly. I see you like the Astro PRN1, but if I were only going to be using 2-3 different rivnut sizes I might be able to just use the single use Wrench-Driven Rivet Nut Tools from McMaster.

[KehlPetersen]

Thank you for this video and all your other videos - what is your level of concern with a hydronic system spliced into the engine coolant lines in terms of the impact on engine operation if you have a line fault (cut/etc.) or an issue with the other hydronic loop equipment? I wonder if a stand alone hydronic system is safer but of course you can't take advance of the engine "free" heating while driving! Also, I want to ensure I have a 4-season van so what issues, if any, do you see with having so many of the system elements under the van and exposed to cold temperatures - like a trip to Alaska in winter? Thanks

[CiviL_Machine]

Bracket master. Methodical fabrication and routing. Machine tool skills. Appreciate you posting this. SUBSCRIBED

[leahptp]

Great explanation, but background music is too loud. Difficult to concentrate on what you’re saying.

[kingofswamis]

Periodically I come up with ideas could be no Bueno, Could be V-MOST. Is there a place to message you direct on here?

[_DarkDwellings]

This is high IQ stuff. All while wearing authentic Crocs?!….sheesh

[kingofswamis]

Incredibly detailed list of items needed on this job. Thank you thank you. 🙏 Thank you. Hey let me know when the horn bracket and cable come in. Gotta do some honky Tonkinin

[renzo]

Sweet content! Not sure if I'm here just for the entertaining music vids or your mad skills at engineering van stuff. The heat exchanger you're using- is it a 10 plate or 20 plate heat exchanger? Thanks and cheers from Nova Scotia 🇨🇦 ✌️

[zenandtheartoflife]

Your girl seems nice but she's just totally off base on the cover. I mean, you nailed it bro. Anyhow, I definitely appreciate the attention to detail and overall breadth of skills used to put this install together. There was one moment that corresponds to something I'm planning on incorporating into my own system, with controlling the D5 using the cerbo gx. You may be thinking cabin temp, but I'm more concerned with the temp of the fresh water in the isotemp (freezing would be bad). With shore power, I don't mind running the heating element to protect from freezing. When remote, I believe having the D5 kick on when water temps in the tank get low may be a good idea. I don't have your level of ambition so I'll just end up taping a sensor to the output pipe on the ISO and insulating it well. But I'm sure you could come up with a much cleaner way to design/build a sensor (maybe an inline probe in a custom machined fitting?) Or, maybe you figure out a better place in the ISO to put the sensor. Anyhow, I will be watching for whatever you decide to do to integrate your heating system with the Cerbo GX.

[lkazanov]

Todd, a question. Why did you choose to create hot water via a tank vs a heat exchanger? I thought that was the whole point with hydronic systems. You could avoid a water tank in lieu of a heat exchanger. Were you concerned of the proposed 1 gallon per minute limitation through the heat exchanger?? Very curious as to your thought process (which I hold in high regard).

[geekazoid]

Just a note here; you've put your HE in series with the heater core but the recommended method is in parallel. I honestly thing your approach is fine. Also this is almost identical to my MY2017 3.0L V6. Clever location for your HE.

[princexavier]

This is a better install than I have seen even professional shops do. And the singing at the beginning is clutch. BRAVO. When I have the money, I would gladly pay to have you do this install for me.

[lkazanov]

Very cool!! The only downside I see is lack of electric plug in backup for the hydronic system. But you get a much bigger water tank. I'm thinking of Aquahot as a comparison. I am blown away at your level of detail and sophistication. You easily surpass a mechanical engineer level.

[tonyhernandez]

Bro. Did u just say San Rafael ?? I jus purchased a used van Can we meet up Would like to pick ur brain for my conversion

[osmyoz]

Whoaaa man that is neat !! Thanks a lot...