Campervan cupboards from lightweight Aluminium, 80/20.

I hope this video gives others enough information to help them make their own super strong and lightweight camper van furniture.
I've opted not to use wood, glued and screwed together, in my opinion this is stronger, lighter and safer than what most choose to do, however it's a little more expensive and involves research and more tools.
I've used lightweight Poplar ply and Acrylic lacquer together with 30x30 aluminium profile.

[@dandy336]

What an excellent video. I've watched loads of van life conversions with 80/20 and none of them got even close to the level of quality here. Nice job.

[@jimmyfavereau]

that strength test had me on pins and needles! well done and thanks for the share

[@lawrencepatricio5776]

I watched several videos of making cabinets using 8020. And your video was the first one that I really understood how to do it. Simple and straightforward. Thank you!

[@gadgetfellow]

I spy an engineer at work..... beautiful work.

[@kangapoopradjan4426]

Simple idea but clearly well thought out constructed & installed 🙂 The only thing I think is missing was the weight of the completed cupboards cupboards & a list of quantities used which would allow others to compare what they have to this well engineered solution Well done great video too👍

[@GaryATC]

From a while back, The 30x30 weighs approximately .9 kg/mt. The long door side used 8mts in total (7.2kg). The shorter side used 6mts (5.4kg). The lightweight Poplar ply weighs less than 2 kgs. I hope this helps you decide the lightest and strongest options

[@rafalkwiatkowski1973]

One of the best method to make those cupboards in a capervan. Beautifully done and well explained. Good luck with your trips.

[@GaryATC]

Doing just that.

[@rafalkwiatkowski1973]

@@GaryATC where did you purchase all of the aluminium and fittings? Thanks

[@123deltree]

hi The helpful guy waited two long for a fantastic way to put selfs in my van thank you,

[@lovemachinecolin]

Excellent piece of engineering sir.

[@georgewashington938]

very helpful video. brilliant job on the cabinets

[@drewhodge3820]

You make that look really easy with those fixtures. I bet it takes me 10x longer to build my cupboards.

[@christinamacintyre9972]

Awesome video - and ask everyone has said here you made that look very easy and you really explained everything. I know you put a lot of work into that plan and to get everything sorted before hand - well done you really looking forward to watching the rest of your videos

[@JensMHA]

Proper good video that. Kudos for undertaking it. I will need to ponder some on it, due to my van being a VW T4 SWB, so the cupboard needs to go side to side, and not along one side. This one gave me some ideas. Thumbs up and all that. 🙂

[@cuongdao5359]

Thanks for the video, I was searching for something like this. 👍 awesome

[@GaryATC]

Thanks. I'm still learning.

[@robertturner4225]

lovely job

[@GaryATC]

Thanks Rob

[@jessestrum]

very clever i like it

[@fibranijevidra]

Well done!

[@goingmouch3753]

WOW WOW…best one I’ve seen so far, excellent work sir!!! Question, the black plastic door runners…where did you purchase them from? Thanks

[@gayehughes5876]

This is the best cupboard tutorial. Thank you so much. May I have the exact items used? Particularly the nuts and bolts. Thx

[@GaryATC]

Google KJN / Bosch Rexroth range

[@stevebrown6665]

Brilliant!

[@julianpowell6355]

Great vid. On my 2nd build now and had not thought of using that system, although I was aware of it. Haven't seen the rails for the sliding doors anywhere though.

[@GaryATC]

Google Bosch Rexroth 3842 526 588

[@julianpowell6355]

@@GaryATC I can see the one problem is getting the cupboard end panels in without having a gap.

[@StevenLewis-HDI-Tuning]

You should do a van tour of my van ;)

[@Skorpioman67]

Great video. I more or less copied your design and approach in mine Oldtimer Mercedes O309D van I’m restoring, got one frame up and looks fantastic. Did you use the same size 9mm ply all around the cabinet incl. the base?

[@whomarjb]

Those door slides are a heck of a find, I've also used 3030 for my cabinets and I'm about to finish the doors, these are a great idea. My channel has my cabinet builds. Thanks for a great video

[@paulsonntag4076]

Clever and inspiring. Would you mind sharing what the sliding rail for the doors is named? It is such a unique item I cannot find easily in the USA.

[@GaryATC]

Bought in uk. www.part-on.co.uk/product/8mm-slot-sliding-door-profile-3842526588-3842555262/

[@travellingjournalist966]

Hi great how to video, where did you get the 30x30 from

[@TheShadowVortX]

Interesting! How are you preventing to create a "cold bridge" from the outside, as basically now the outer skin of the van and the interior cabinets are connected? or In a cold day, do you feel the outside temperature through the cabinets? Thanks in advance for your input!

[@JonNewlyn]

Thank you for your clear and concise video. We are doing the same in our van. Question, where did you the end connectors? I have various but not those.

[@GaryATC]

The connection on the corner is made with "quick connecters" you will need a jig to drill those. I had one made but they can be bought. Feel free to contact me.

[@RyanAndersonCO]

@@GaryATC Thank you for the video! I've searched and searched for these "quick connectors and cant find anything like you used. Do you possibly have a link to them?

[@JW-rq1ik]

Thank you for the video. I would like to emulate your approach, but it is not obvious to me how you were able to slide such long 80/20 rails onto the bolts in the ceiling and the side wall with the windshield in the front. Can you please explain?

[@Edgunsuk]

any links to where you got the aluminium also is there a build video as i simply wont know the names of the different components angles curves end plugs ? no idea cheers

[@brianchetelat6601]

Love the work. Can you please tell me what those Allen Screw Connectors are called and where I might find them? Thank you for sharing.

[@GaryATC]

KJN quick connectors.

[@brianchetelat6601]

@@GaryATC I'm guessing not available in the US?

[@danielritson1856]

Great video, could you advise me on where you purchased the black slider profile? It's what I need for my build

[@GaryATC]

Both the UK supplier's stock it but don't list it online.

[@daviddickson3181]

This looks amazing. Would you consider doing this for customers?

[@GaryATC]

I don't have enough time to work on my own camper. Don't mind giving advice though.

[@bluetrees5936]

Great video! Would it be possible to post links to the suppliers and part numbers please? I’m going to make these now I’ve seen how good they are!😊

[@GaryATC]

Google KJN

[@stephenbulmer7148]

Great little video showing a good build method, thank you. Where did you get those alternative rivnuts from? I can't seem to find them, cheers👍👍

[@GaryATC]

They are called "Versa nuts". I managed to get 25 as a sample.

[@stephenbulmer7148]

@@GaryATC awesome thank you. You wouldn't be able to tell me where you got them from, don't mind paying for them. Your video has given me more confidence to use the same produces for my build, it looks so strong. Thank you

[@GaryATC]

I couldn't buy them online, I googled and ended up calling, asking a few companies for a small amount, I don't remember which.

[@m.r.4798]

Here in the US the Versa Nuts are most often referred to as Plus Nuts. Perhaps you have more luck finding them under that search term.

[@ratemynuts]

I think I'll build my van using this stuff, looks much better than I expected. How do you get the end triangle in?

[@bigaldo8187]

See video at 9:50

[@GaryATC]

They are called "Versa nuts". I was able to order 25 as a sample, which is all I needed.

[@AdrenalineWings]

amazing Where in the uk did you buy your 80/20 from? Thanks

[@GaryATC]

KJN

[@mrcagas1158]

Where do you buy the profile and fitting from.

[@philwilliams23]

Great video just need to find a supplier of this 80/20. Only seem to sell it commercially, any ideas where I can source this from please? Looking to make kitchen and overhead storage like yourself. Many thanks.

[@GaryATC]

Just Google 3030 profile. Two UK suppliers.

[@kaywackwitz175]

Great Video! I'm using the same building technique and wonder which thickness each spacer had (the 2° spacer on the ceiling and the 8,5° spacer on the side)?

[@GaryATC]

Ceiling zero. There's enough flex. 8-10 on the sides is plenty. There is flex in the panels so don't worry BTW don't use rivnuts. Terrible things. Try "Versu" nuts. Just like you use on dry lining board.

[@kaywackwitz175]

@@GaryATC Great, thanks. Here in Germany, they are called plus-nuts. 🙂 Do you remember to what length you cut the top and side round-bar spacers?

[@Wipedout63]

Hi. Great build. Can I ask where you got the tracks for the sliding doors? Thanks

[@GaryATC]

KJN or Part-on both sell them.

[@Wipedout63]

@@GaryATC thanks

[@bvinderbarrah8531]

Hi been watching your video very good idea Could you please put up a link for supplies of the plastic runners thank you

[@GaryATC]

KJN Google them.

[@bvinderbarrah8531]

Thank you

[@helloiamjoshie]

Thanks for the video! Versa nuts?

[@m.r.4798]

In the US they are calmed mostly Plus Nuts.

[@maxpower9340]

Could you tell us were you got the kit, aluminium extrusions, nuts versanuts?

[@GaryATC]

In America they call it 80/20, here in the UK we call it extruded Aluminium profile, it's made mainly by Bosch Rexroth, and sold by two main suppliers in the UK. Sizes I tried were 40x40mm for the roof rack solar and 30x30mm for the interior. There are lots of ways to fix it together, you'll need a good quality blade to cut it and accuracy is key. There is no "give or take", it has to be mm perfect and cut to exactly 90°. Both UK suppliers do their own version which is less expensive. If you look at KJN profiles site it will show different fixings. I bought a lot of mine from Amazon and eBay too. It weighs less than 1kg/mt. My upper cupboards (both sides) weigh less than 13kg, and they are strong. If you're near Bristol I could demonstrate.

[@DavidandLynnTownsend-xx1lv]

Do you have a link to where you found the black channel pieces that the cabinet doors slide on?

[@GaryATC]

Part-on do them in Birmingham

[@philwilliams23]

Hi can you tell me what size profile you've used please, is it 20/20?

[@GaryATC]

3030. 2020 is too bendy.

[@dogslife8664]

Where did you get your internal roof panels from?

[@GaryATC]

Mercedes-Benz original fitment.

[@StevenLewis-HDI-Tuning]

So what do you estimate the total weight of each cupboard unit to come out at?

[@GaryATC]

The 30x30 weighs approximately .9 kg/mt. The long door side used 8mts in total (7.2kg). The shorter side used 6mts (5.4kg). The lightweight Poplar ply weighs less than 2 kgs. I hope this helps you decide the lightest and strongest options.

[@angusthomson7381]

I very much doubt you’d get anything lighter and remotely as strong. Great use of available kit. Very impressed

[@GaryATC]

@@angusthomson7381 Thanks, I think this system has a lot of potential, plus I'm still learning how best to use it.

[@StevenLewis-HDI-Tuning]

@@angusthomson7381 yes its miles stronger than my 15mm Morland ply. I definitely couldnt hang off any of my cupboards.

[@onlyinparadise4613]

Excellent video! Are you an engineer? 👏

[@GaryATC]

I consider 'Engineer' to be an academic term, but stuff like this does come easily to me. BTW I'm a farmer of sorts.

[@onlyinparadise4613]

@@GaryATC you are awesome 👏