Pro Tips: Building Van Upper Cabinets Using 8020 (Extruded Aluminum)

We share our top tips for building van upper cabinets using extruded aluminum (8020).
DIY VAN BUILD PRODUCTS: www.thrivecraftedvans.com/bui...
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Where we buy our extruded aluminum bars and hardware:
tinyurl.com/24m52thp
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5/32" Allen Wrench: amzn.to/3vdfnOk
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➳ CONNECT WITH US:
Instagram: @thrivans
Collaboration: [e-mail]
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➳ WHO WE ARE
We're Lisa & Jeff Warnick and we've been repping Thrive freeze-dried foods for over 10 years. It's been a dream of ours to have a van to travel the country, supporting our team and sharing the Thrive love. After we built our first van, we realized how much we love the creative process of designing and building vans...so now we're building and selling our own custom vans. We also do conversions on client-owned vans. In this video
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ABOUT
We share all our tips and tricks for building upper cabinets using extruded aluminum (8020).
#vanlife #vanconversion #vanbuild #freezedried
⏰ TIMECODES
0:00 Intro
0:30 Extrusions we use
2:15 Fasteners we use
7:55 Attaching cabinet to van
10:07 Lining the cabinets
12:58 Utrusta Hinges
17:42 Where we buy extruded aluminum
Disclosures: All opinions are my own. Sponsors are acknowledged. Some links in the description are affiliate links that if you click on one of the product links, I’ll receive a commission at no additional cost to you. As an Amazon Associate we earn a small commission from qualifying purchases.

[@Jet-Levi]

Jeff, The guidance that you provide in your videos is some of the best on KZbin (and I watch a lot of YT). Thank you.

[@TeutonicNordwind]

This is just excellent, Jeff! The couple videos on the Ikea "Utrusta" hinges that you've done have convinced me to use them on our pending first van build.

[@OurThrivingLife]

Glad it was helpful!

[@BiggsiesGarage]

Thank you for sharing your tips and tricks. I am starting my planning and design for a overland truck with a built on camper... your information is helping me with how I can go lighter on the inside after I have built out the box on the truck frame. Oh yea and yes the Thrive Life Food is unbelievably tasty and easy to make. absolutely love it.

[@OurThrivingLife]

Glad we can help. Good luck with your truck conversion.

[@stevehori673]

That’s funny Jeff I use the same graph paper memo pad and draw out my plans like you do. Helps me with the cut list but also to make sure I have enough screws, t-nuts and brackets. TNUTZ are the best for basic stuff but I have to use 8020 for specialty pieces. Great video! If I didn’t build my own van I would come to you for a custom.

[@OurThrivingLife]

Yes. There are still a few part we have to order from 8020.

[@vandaddy-o2732]

Good stuff... thanks for the video!

[@OurThrivingLife]

You bet!

[@user-jb8bg7sq5p]

very informative and well explained video thank you!!

[@OurThrivingLife]

Glad it was helpful!

[@johnjarvinen1450]

Thank you!

[@OurThrivingLife]

You're welcome!

[@rogerkamp8817]

Thanks for sharing your knowledge. How do you mount the microwave to the 8020 framing? If the microwave is installed, how do you get access to screw the 8020 framing to the van?

[@Jarin22]

Hey Jeff, Awesome videos, they have been helping a lot. My wife and I are currently building our first van. How do you attach the utrusta hinge to the 80/20? Do you use the hardware included with the hinge or do you put a tnut in the 80/20 and attach it that way? Thanks for all the help

[@OurThrivingLife]

Good question. We screw the hinges directly into the 8020 bar. We use the same size screws that come with the hinges, but stainless steel. They are a little stronger. The ones that come with the hinges break easily.

[@alanhat5252]

​@@OurThrivingLifeyou've given 2 different answers to this question?

[@tommyc1028]

Thank you, Jeff I’ve been a follow of your channel for quite some time, and I love your van builds… this video, as well as the one you posted most recently on extruded Aluminum was so helpful. I am absolutely ordering a bunch of it for my build… I have one question about how you mounted the UTRUSTA… were you able to use the supplied IKEA hardware? Or did you use different screws to mount it into a t-nut in the 8020? Thanks

[@OurThrivingLife]

Thanks for watching. I buy sheet metal screws and go directly into the aluminum bar. The screws supplied with the hinges break easily.

[@alanhat5252]

​@@OurThrivingLifeyou've given 2 different answers to this question?

[@DavidAbbott64]

Awsome Jeff, just starting to plan the build these cabnets are great, can we buy the plans to build our own??. Keep up the great content!

[@OurThrivingLife]

Sorry. We currently sketch everything out on paper and don’t have drawings to share.

[@jasonwilly2025]

ANOTHER great video! Thanks Jeff. Do you have a linke for the ABS panels?

[@OurThrivingLife]

We get the ABS from a local supplier, Spandex USA.

[@shannagachen]

Fantastic video Jeff! I'm learning so much. What material / thickness do you use for the bottom of the upper cabinets and do you slide it into the grooves of the extruded aluminum to secure it? Thanks!

[@OurThrivingLife]

We use 1/4" plywood and slide it into the slots in extruded aluminum.

[@stevemccaskey4416]

Thank you for the video. What thickness of abs sheet do you use?

[@OurThrivingLife]

0.060” thick.

[@thebg7532]

Another great video! Thank you for sharing, Jeff! Could you kindly provide information on the type and where to order ABS for the cabinet back panel?

[@OurThrivingLife]

We get it from a local plastics and sign making supplier, Spandex USA.

[@usaroseinc]

Jeff thanks for another inspiring video - I have a question re the upper shelving size (in a 144 MB) - dont want too big or too small - strick out too far and bump your head - too shallow - lots of work for the trouble. I am thinking 12.5 - 13” deep and 24-30 wide then of course what is the ABS size i will need for the ideal size not too loose or too tight. I know you worked this all out the hard and $$$ way and I do appreciate that and your feedback too would be a big help to the DIY guys out there. -Thanks again for a great channel.

[@alanhat5252]

​@@OurThrivingLifehow do you work out what size ABS sheet you need?

[@alanhat5252]

​@@OurThrivingLifeis ABS better than PVC or some other material? Why?

[@VintageFilmChannel]

I am curious about using the inside corner brackets for the front face. Hidden Corner HC-10. Is there a reason for not using this bracket?

[@OurThrivingLife]

That will work. There are usually several options for each connection.

[@fredfalco5204]

Jeff, Got a question on most van builds. You use plywood strips to attach the wall panels. When you use the 8020 you attach the cabinets differently and I don’t see any wood under the cabinets. How do I attach the walls? Thanks for your help.

[@OurThrivingLife]

We usually use Shiplap. We use marine adhesive and pin nails to attach it to furring strips. When doing panel walls we screw directly into the metal of the van.

[@nebulight]

For the abs panel, you mention it sits in the groove for the top but does it not sit in the groove in the lower back piece? If not how do you get it to stay in place? Thanks!

[@OurThrivingLife]

Good question. It just rests against the back bar and the bottom of the cabinet. You can put it in the back groove, but you’ll have to notch it around the brackets. We’ve found it looks cleaner the way we do it.

[@nebulight]

@@OurThrivingLife so it doesn’t slide forward? Or is it behind the rear extrusion?

[@richardsracingmad]

In UK, which size extrusion for floor cabinets 20mm (0.78”) or 30mm (1.18”)? And top cabinets? The bed I am using 40mm (1.57”)

[@OurThrivingLife]

I haven’t used metric versions, but I’d probably try the 30mm.

[@Cwunchy_dog]

Where do you buy the white ABS plastics?

[@OurThrivingLife]

We get it from a local supplier in Salt Lake City called Spandex USA.

[@kevinschmidt6346]

What size abs plastic sheets do you buy for the upper cabinets?

[@OurThrivingLife]

4’ x 8’ x 0.060” thick.

[@kevinschmidt6346]

Thanks!

[@envj8813]

If you skip the middle man and order directly from a manufacturer you can get it cheaper. Shipping would be more but still overall better pricing. I got 3030 3m pieces for $11.40 each and the ones with 2 smooth sides were $14.24 each for 3m. 4040 was $14.29. T nuts were $.03 each. 90° brackets were $.30- $.38 a piece.

[@tc.]

Would you mind sharing the contact/URL to the manufacturer? Thanks!

[@envj8813]

@tc. ask for Boaz zhang. He pretty quick to respond and will give you a quote for what you're looking for

[@envj8813]

@@tc. I posted the link on your last video