The walls, floors, and ceilings are the foundation of your campervan's interior, transforming the bare metal shell into a functional and inviting living space. This guide equips you with the knowledge to confidently tackle building these essential components, providing a solid base for your dream campervan conversion.
Choosing the right materials depends on several factors like weight, durability, moisture resistance, aesthetics, and budget. Here's a breakdown of popular options to consider for each component:
Plywood: A classic and affordable choice, plywood offers good strength and can be painted or stained to match your desired look. Opt for lightweight options like luan or birch to minimize van weight.
Wood Panels: Engineered wood panels like MDF or laminate provide a smooth surface and come in a variety of colors and wood grain patterns. They are generally more expensive than plywood but require less finishing work.
PVC Wall Panels: Lightweight and moisture-resistant, PVC wall panels are a great choice for bathrooms and kitchens due to their easy cleanability. They come in a variety of styles and colors to suit your taste.
Fiberglass Reinforced Plastic (FRP) Panels: Highly durable and waterproof, FRP panels are ideal for high-traffic areas or those prone to moisture like shower surrounds and countertops. They are easy to clean and maintain but can be more expensive than other options.
Fabric Wall Coverings: For a softer touch, consider lightweight fabric wall coverings like vinyl upholstery or sailcloth. These options can help with noise dampening but require careful consideration of moisture management and ventilation.
Treated Plywood: A budget-friendly option, treated plywood provides a solid base for other flooring materials. Ensure you use a high-quality wood sealant to protect it from moisture.
XPS Foam Board: Lightweight and insulating, XPS foam boards create a comfortable walking surface and can be used as a subfloor before installing other flooring materials like vinyl or linoleum.
Vinyl Flooring: A popular choice for its durability, waterproof nature, and variety of styles, vinyl flooring is easy to clean and maintain. Choose plank styles for a wood-look or sheet vinyl for a seamless appearance.
Laminate Flooring: Offering the look of wood at a more affordable price point, laminate flooring is moderately water-resistant and fairly easy to install. However, it can be slippery when wet and may not withstand heavy abuse.
Bamboo Flooring: A sustainable and eco-friendly choice, bamboo flooring is hardwearing and naturally water-resistant. It adds a unique aesthetic but can be more expensive than other options.
Weight: Every pound counts in a campervan. Choose lightweight materials for walls, floors, and ceilings to optimize fuel efficiency.
Moisture Resistance: Especially important in kitchens and bathrooms, moisture resistance ensures your walls and floors can withstand water exposure without warping or mildewing.
Aesthetics: Don't forget the visual appeal! Choose materials and finishes that complement your overall design scheme and create a comfortable living space. Consider factors like color, texture, and pattern cohesion across walls, floors, and ceilings.
Maintenance: Think about the effort involved in maintaining different materials. For example, wood panels might require repainting over time, while vinyl flooring is generally easy to clean with regular sweeping and mopping.
Functionality: Prioritize materials that suit your vanlife activities. For instance, if you plan to mount shelves or cabinets on the walls, choose materials with sufficient strength to support the weight. Similarly, consider flooring options that can handle high traffic and potential spills if you have furry travel companions.
Ventilation: Especially important when using moisture-resistant materials like vinyl or FRP panels, ensure proper ventilation within your van to prevent moisture build-up and condensation. This might involve installing vents in your walls and ceiling to facilitate air circulation.
Before diving headfirst into building your campervan's walls, floors, and ceilings, meticulous planning and preparation are crucial for a smooth and successful build. Here's a breakdown of key steps to ensure you're well-equipped to tackle this stage:
Template Triumph:
Measure Twice, Cut Once: Grab a tape measure and meticulously measure the interior dimensions of your van. Pay close attention to variations in width and height due to wheel wells, flaring walls, and other structural features.
Cardboard Companions: Craft templates out of cardboard for each wall panel, ceiling section, and floor cutout. Cardboard is inexpensive and easy to work with, allowing you to refine the design and ensure a precise fit before committing to cutting your actual wall and ceiling materials.
Marking Marvels: Clearly mark each template with its corresponding location on the van (e.g., "Left Rear Wall"). This simplifies the installation process and prevents confusion when attaching the finished panels.
Demolition Decisions:
Assess Existing Walls: If your van has existing interior wall panels, carefully remove them to expose the van's metal ribs and facilitate insulation installation. Salvage any panels in good condition for potential reuse in other areas of your build.
Mind the Wires: When removing existing panels, be wary of any electrical wiring that might be behind them. Turn off electrical power to the van and consult a professional electrician if uncertain about wire placement.
The Insulating Act (Refer to Insulation Guide):
Refer to Your Insulation Guide: Before building walls, floors, and ceilings, it's essential to install insulation between the van's metal ribs (walls and ceilings) or floor joists (floors). Refer back to our comprehensive insulation guide to choose the appropriate insulation type based on your climate and budget. The guide provides detailed instructions on cutting, installing, and sealing the insulation material.
Material Selection & Acquisition:
Choosing Your Champions: Select the materials you'll be using for your walls, floors, and ceilings based on factors like weight, durability, moisture resistance, aesthetics, and budget. Popular options include plywood, wood panels, FRP panels (floors), and vinyl flooring.
Quantity Calculations: Once you have your wall and ceiling templates, calculate the total amount of material needed. Factor in a little extra for potential cut mistakes and allowances for trimming during installation.
Shop Savvy: Compare prices and quality across different lumberyards and home improvement stores. Consider online retailers for certain materials, but factor in shipping costs. Salvaged materials can be a budget-friendly option, but ensure they are in good condition and suitable for your build.
Gather Your Arsenal:
Tools of the Trade: Assemble the necessary tools for the job. This typically includes a jigsaw or circular saw for cutting panels, a drill with various drill bits for fastening materials, sandpaper for smoothing rough edges, a staple gun (optional for temporary holding), and a construction adhesive appropriate for bonding your chosen materials.
By following these comprehensive planning and preparation steps, you'll lay a solid foundation for a successful build.
Now that you've meticulously planned and gathered your materials, it's time to bring your campervan's interior to life!
Framing (For thicker walls or added support):
Cut wood studs to size based on the desired wall thickness and the distance between the van's ribs.
Apply construction adhesive to the backs of the studs and secure them vertically between the ribs using screws. Ensure studs are aligned with those planned for the ceiling for a seamless connection.
Creating Furring Strips:
Cut wood battens to size based on the depth of your chosen wall material (plywood, panels, etc.)
Attach the battens horizontally to the interior of the framed walls (or directly to the insulation if not framing) using screws and construction adhesive. These battens create a crucial air gap that allows for moisture circulation and prevents condensation between the wall material and the insulation.
Cutting & Attaching Wall Panels:
Using your pre-made templates as a guide, meticulously cut your chosen wall material (plywood, wood panels, etc.) to size with a jigsaw or circular saw. Wear safety glasses and hearing protection while using these power tools.
Apply construction adhesive to the backside of each wall panel, ensuring even distribution.
Carefully position the panel against the furring strips and secure it using screws. Ensure a flush fit between panels and use sandpaper to smooth out any rough edges.
Mirroring the Walls:
Similar to the walls, attach horizontal wood battens to the van's ceiling ribs or directly to the insulation to create furring strips. Ensure proper spacing to accommodate your ceiling panels.
Cutting & Attaching Ceiling Panels:
Employ your templates to cut ceiling panels from your chosen material.
Apply construction adhesive to the back of each panel and carefully secure them to the furring strips with screws. Pay close attention to seams and ensure a level finished ceiling.
Subflooring Foundation:
Cut your chosen subflooring material (treated plywood, XPS foam board, etc.) to size, ensuring all pieces fit together snugly.
Secure the subflooring pieces to the van's floor joists (if present) or directly to the metal floor using construction adhesive and screws. Ensure proper ventilation by leaving small gaps near the bottom edges (covered by trim later) to prevent moisture buildup.
Considering Additional Flooring:
If you plan on installing additional flooring material like vinyl or laminate, refer to the specific manufacturer's instructions for installation over your chosen subfloor.
Filling Gaps & Trimming:
Use caulk or filler to address any small gaps between wall panels, ceiling panels, or floor subflooring sections. Once cured, sand smooth any excess filler.
Installing Trim:
Decorative trim pieces can be added along wall edges, ceilings, and floor bases to conceal seams and create a finished look. Choose trim made from a lightweight material like PVC to minimize weight impact.
By following these steps and adapting them to your chosen materials and van layout, you'll transform the bare metal shell of your campervan into a solid foundation ready for further customization. Remember, meticulous planning and careful execution are key to achieving a functional, durable, and aesthetically pleasing interior for your dream adventure mobile. So, grab your tools, unleash your creativity, and get ready to build the campervan of your dreams!