van conversion how to

Building Cabinet Frames in Your DIY Van Conversion

This can be one of the more daunting tasks but you will be amazed by what you can do with your creativity here.  Get your measuring tape out because you will be using it a lot in this step.

We've built cabinet frames both inside the van and in the shop and we've realized it’s a bit easier to build all the frames outside of the van.  We also wanted to make all the framing out of steel. So that way, it will be extremely durable and will be able to take all the vibrations that the van will be provided along the journey.  

Welding all the frames was an arduous task and we would probably not do it again simply because working with wood is so much easier and quicker.  With that being said, if you’re up to the challenge we think that the steel frames are more lightweight than wood because they require so much less material and are much stronger than the wood framing.  Welding all the cabinet frames took us much longer than anticipated, but the result is so much cleaner and stronger. So, it was worth every second.  

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After measuring space and drawing it out many times, we were ready to make our first frames.  On the van's floor, we use masking tape to tape out the size of all cabinet bases to get an idea of how much space we will have. We measure the sizes between the tape and sketch up some drawings. Then, we always start with the cabinets' base and build them up from there, always referring to our drawings as we go.  You will need to account for building in a curved structure, so most times, the base dimensions will be much different from the top dimensions.  This is where your drawings and measurements need to be on point, or you'll be reworking some of your masterpieces. 

You will also want to become best friends with your T-Square to make sure every aspect of your framing is square.  If not, you will have some difficulties getting your drawers to slide smooth or having a level countertop.  

We like to start with our largest cabinets, first. Then, do all the smaller upper cabinets later. So that way, we can see what the dimensions of the upper cabinets need to be to still have headroom and ample space to feel comfortable.  Since there is no right or wrong way to build a van, you’ll notice it’s very ambiguous to choose dimensions for some of these cabinets.  Not all builds are alike. Sometimes, you gotta bend the rules a bit to make something fit.  That’s why it’s easiest to build large items, first, like beds and tall cabinets. Then, work around them, while making countless drawings, to get your space perfect for you.  

Once everything is framed and fits into the van perfectly and you are happy with your frames. It’s much easier to paint the cabinet frames now, outside of the van, compared to when they are installed inside the van. Since we welded all of our frames, we first needed to clean all the metal with acetone before we spray painted everything black. Painting the steel frames is very crucial otherwise all the frames will rust and not look very nice as a finished product.

Once your cabinets are all framed up, you’ll need to secure them to the van walls.  This is where your original layout design will payoff.  Hopefully you framed your wall up so that everything can be easily attached to the framing, securely. You'll want to screw in the base to the van floor and the backs of the cabinets to the framing behind your walls. 

After you have all your framing installed in the van, you will really feel accomplished and your van will really start to take shape here.  The sky’s the limit for creativity in your van build. Just remember to do what works best for you and your space. 

How to build cabinets in a van - Match the curve of the van every time

After you have built all your cabinet frames and have them securely installed into your rig, it’s now time to cover up the sides to all the cabinets and get them looking professional.  This process is called scribing and if you put in the time here your results will look amazing. 

To start, what you will need for this task is some Ram Board or cardboard to make stencils of all your cabinet sides.  We used a razor and a large T-Square to cut them all.  From here, you will want to trace all these stencils to MDF particle panel, which is a thin particle board.  It’s best to have your cardboard stencils be more on the larger size. So when you go to scribe the sides of the MDF, you won’t cut the stencil to small.  

What you’ll do here is take the particle panel and place it on the side of the cabinet you need to cover. You will want your particle board to be a little longer and taller than your desired size of the cabinet side because you are going to scribe it down to size.

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To do this, you need to hold your marker or pencil in your hand. I like to have the outside of my hand touching the van wall, as I drag the pen down to trace the curve of the van onto the particle panel.

From our quick “How to build a shelf in a Van” video on our YouTube channel. This video is great if you have been fighting with those van curves. This will show you how to conquer those curves for good!

From our quick “How to build a shelf in a Van” video on our YouTube channel. This video is great if you have been fighting with those van curves. This will show you how to conquer those curves for good!

Now, you’ll want to cut the particle panel with a jigsaw, you’ll want to cut a few 1/16”ths of an inch before the line to leave some of the line.  This will allow you to get the scribed side perfect with your sander. 

How to build a cabinet in a van

Once you’ve made the cut, take your sander and sand down to your line. The sander allows you to be more precise than the saw.   

Building van cabinets

Now that you have your particle panel templates perfect, you will want to transfer them to your plywood or whatever material you’re using for your cabinet sides.  This is the exact same process as you did with the cardboard to particle panel. You’ll just want to be careful now to get it perfect.

building van cabinets

Once you’ve scribed, cut, and sanded your side panels, you’ll now need to paint or stain them before you install to make your life easier.  We went with a nice turquoise/teal stain for most of our cabinets and left our uppers natural with a polyurethane clear stain. We highly recommend using a sealer, as well here, to help protect the stain from water and any potential vancidents.  

Now, you’ll want to attach your sides to your cabinets.  If you welded all your frames like us, you’ll need to drill plenty of holes before hand to attach all the sides.  With wood, it’s simple. Just screw the sides onto your frames.  

This step requires a lot of patience, we highly recommend using the particle panel after the cardboard.  This was our first time doing this, we would usually just go off the cardboard but the partial panel is more rigid and allows you to get a perfect fit on all your cabinets.  It’s an extra step in the process but it is worth it.  

12 Volt Van Conversion Battery Basics and Wiring Diagram 

How to wire your battery bank in parallel

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Once you’ve picked out the perfect location for your battery bank to live, you'll need to start wiring the batteries in Parallel.  This is an easy process and you’ll learn a lot along the way.  

What you will need here to get the job done is: (Amazon Affiliate Links)

2 or more 12 Volt AGM Batteries - https://amzn.to/2P1c4Bp

8 AWG Cable - https://amzn.to/37tdZVO

Battery Terminal Kit - https://amzn.to/37wQtr3

Wire Snipper/crimper - https://amzn.to/2V5HoTD

Wiring the batteries in parallel

This is a pretty easy straight forward step. What you want to do is wire all the negative (-) connections together and all the positive (+) connections together. What this will do is it will convert your two 12 volt 100 a/h batteries into a 200 a/h battery bank at 12 volts.  To do this, you will use the 8 AWG cable and cut it to size and crimp on a battery terminal connector.  Make sure you crimp these on as tight as possible, I like to use a vise here and get the connection very solid.  If you have loose terminals, you will have voltage drop and your battery bank won’t be working efficiently.  I also like to use heat shrink here. You don't need a heat gun; a lighter will do the trick. 

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Once you have your batteries wired in parallel, by connecting all the positive terminals to each other and the negative terminals to each other. The next step is to establish a positive ground near the location of the battery bank.  I like to use the chassis of the vehicle for this.  What I do is drill a hole in the body of the van.  You will want to sand all the paint and metal shavings off so that you have an metal on metal contact.  Now, you will just put a bolt and some washers through the body of the van and make sure you tighten this bolt as tight as you can get it.  If you have a bad ground, you will have voltage drop and all kinds of issues with your system. So establishing a solid ground is very critical to the efficiency of your power system.  

Now that you have your ground connection bolted in and solid, you are ready to build a sturdy frame for your batteries to live in.  This is important to keep the batteries from not only sliding around, but also becoming projectiles.  You'll want to secure the battery frame to the floor of the van.  You can make this out of wood or metal.  We are lucky enough to have access to a welder. So, we constructed a very secure metal battery bank box.  On previous builds, we have just build a wood frame that fit the batteries perfectly and we never had issues with it. Now you are ready to start running your wire.  We’ve included a free wiring diagram below to help you get started.

Download free wiring Guide for your camper van!

Download free wiring Guide for your camper van!