Van Cabinetry: Wood vs. 8020 (extruded aluminum) | Full-time Builder Shares Pro Tips

Discussion of van construction using wood vs 8020 (extruded aluminum).
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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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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.

[@bjbhehir]

I built my van about 4 years ago with 80/20. I used 1515 series for everything, I haven't had to tighten anything in 4 years, I didn't use lock tight. I was amazed how tight everything was when I built it and everything comes out square with 80/20!! There is a small learning curve but it's really simple!! I still have zero squeaks or rattles.

[@Imogeechoo]

This is some of the best objective advise I have come across, thank you so much for putting this in excellent perspective.

[@douglasmowat7143]

I designed my stealth camper using extruded aluminium for everything upper cabinets and all I have used some wood to slide into the slots in the aluminium.for facing doors and panels I used sheets made from a plastic faced on both sides with aluminium. Now 8 years of constant use. Still like new. I'm very thankful for a skilled builder for putting everything together. As I am becoming more infirm my needs have changes and I would like some alterations. The adaptability and re-usability of the aluminium will enable this . I'm thrilled to have found your website. And will follow your open minded, yet cautious approach

[@ziasiddique1800]

Thank you. Love you’re videos

[@openwatergo]

Thank you for creating what I think is the single most practical and complete end-2-end video on 80/20. I can't wait to watch your other videos, particularly regarding the uppers. I'd also very much appreciate your thoughts on wall framing and to what extent you use 80/20, if any, in the walls. Please continue to add such great content.

[@digb1]

Excellent primer on 8020. Many thanks from the UK

[@TeutonicNordwind]

Playing some catch up of fave YT channels. Excellent as usual, Jeff! Thanks for sharing the tips and your expertise.

[@OurThrivingLife]

Thanks for watching!

[@kennethoros4043]

Thank you for the video. Very informative.

[@OurThrivingLife]

Glad it was helpful!

[@mythicalnomadadventure969]

Excellent explainer about wood vs extruded van build outs. Good philosophy on the two as well. 👍 Rock on 🙂.

[@OurThrivingLife]

Thanks, you too!

[@devondirtdevil8206]

Just about to convert a VW Crafter 4Motion and I have found that your channel is the most informative. Will definitely be using extruded aluminium for my build. Thanks for sharing.

[@OurThrivingLife]

Awesome. Thank you, and good luck with your conversion.

[@h2oespi541]

im building a tiny home and found this video at the RIGHT time

[@jartotable]

Would love to see how you make the bed from it.

[@spindlespringsranch3108]

Excellent video, thank you!

[@jartotable]

I agree with another commenter, I'm always weighing up how will 'this or that' react in a crash. I'd rather metal bend than wood splintering off. This could be definitely incorporated into my van. I've configured my contents so that I'm using only the manufacturers pre-drilled holes with those specific van screw plugs.

[@OurThrivingLife]

Agreed!

[@ifell3]

You know the T-slots in these, how much load can they take before snapping out the profile or the T-nuts failing?

[@najhome3962]

Love the content I just got my Sprinter Van and everything I would be doing is inspired by your videos. Would you refer me to any videos that you might have made where I can see the step by step on how you mount these frames into the wall of the van and the floor?

[@OurThrivingLife]

Thanks for viewing our channel. We currently don’t have any videos on how to secure the cabinets to the van, but we’ll try to do one soon.

[@h2oespi541]

This is awesome guidance! Do you include toe kicks in your cabinets? If so, what guidance do you have for making that design workable.

[@OurThrivingLife]

We do include toe kicks. We just raise the front bar about 4" off the floor. Then we make a small box out of wood, attach it to the floor 4" back from the front of the galley, and then attach a 1/4" panel to the box that matches the cabinets.

[@grwoolf]

Good video. Another cabinet/enclosure framing material to consider is 3/4" steel tubing. Same weight per foot as 10 series 80/20, takes up less space (3/4" vs 1"), no restrictions on angles, and is significantly less expensive. On the downside, more labor/skill required to weld, steel can rust and should be painted, and making adjustments/changes is messy with the cutting/grinding required. If you don't already weld, it's a great excuse to buy a wire-feed welder and learn something new.

[@OurThrivingLife]

Thanks for the info!

[@davidbielski]

How is the sound deadening of extruded aluminum VS wood? I wonder if it rattles more. Thank! Great video

[@OurThrivingLife]

I don't notice a difference. No rattles with aluminum if installed properly.

[@mrbranchatl]

I have been checking out your videos, good stuff. Do you consult on a Ram Promaster?

[@OurThrivingLife]

I have not worked on a Promaster, so if you have questions specific to that van, I’m probably not the best person to ask.

[@mrbranchatl]

@@OurThrivingLife Thanks, you have some awesome how to videos. Will use them as a reference. Thx

[@user-jb5vj9vh2t]

Great video!! As a custom woodworker, I was planning on building all wood cabinets, because that's what I'm used to. But, you bring up some good points in favor of extruded aluminum. Question: do you use a material between the aluminum and van metal, to help prevent thermal transfer?

[@OurThrivingLife]

Thanks. Yes. I make spacers on a 3D printer that go between the aluminum and the walls of the van. You can use composite shims or even 1/4” plywood.

[@user-jb5vj9vh2t]

@@OurThrivingLife Thanks

[@ifell3]

Great 101 👍🏼

[@OurThrivingLife]

Thank you 👍

[@cwareham1]

Hey Jeff - Apologies if I missed it in this video or in the others that you've published, but what size fasteners do you use on the extruded aluminum? Is it a 1/4 20 or 6 mm? Thanks!

[@OurThrivingLife]

Not sure which fasteners you’re asking about. The ones for the brackets? Those are all 1/4” for 10 series aluminum.

[@cwareham1]

@@OurThrivingLife 👍 that's what I meant; is 10 series usually constructed using 1/4-20 rather than m6 unless there's a compelling reason to go with metric?

[@erics5919]

where can you purchase the black hex board panels, you're using for your utility cabinets? Is this birch plywood with a laminate covering material?

[@OurThrivingLife]

It is called Hex Ply, or Riga Heksa. It is Baltic Birch with a phenolic resin laminate on both sides. We order it directly from the supplier, but you have to order a whole pallet. You could check with local lumber suppliers.

[@erics5919]

@@OurThrivingLife Thank you for responding! I'm very impressed with your channel, work and help to DIY'ers.

[@user-zc1hp5cl2g]

I think it’s fairly clear that Alu framing is stronger. However, it does use up more space, than just plywood. Especially in a Sprinter that is already narrow, losing 2”+ of width is a lot.

[@OurThrivingLife]

True, but you're only loosing it along the edges and corners where the framing is. The rest of the interior has the full volume extending to the wood panels. We often have components like water heaters, hoses, wiring, etc. extend all the way to the wood panels. Also, with no back on most of the cabinets, you gain space in the rear. We don't really find that you lose space with the aluminum framing.

[@butch8169]

what flooring do you use? is that vinyl plank or full sheet? TIA.

[@OurThrivingLife]

They are planks. We use Aquaguard from Floor and Decor. Best LVP flooring we've found.

[@tc.]

@@OurThrivingLife Thanks for making such great video! I have a question regarding mounting 8020 cabinets - Do you mount the battery cabinet or the water tank to the floor, down to the van sheet metal, or nothing and only bolt them to the van's side wall with rivnuts? Thanks!

[@butch8169]

@@OurThrivingLife thank you!!

[@H2Dwoat]

Hi, one of my main concerns for building out a van is how it will hold up during a crash. The thought of heavy objects acting as missiles during a crash gives me the ebbie jebbies. 8020 seems to be the best way of mitigating the risks but I could be completely wrong, any thoughts?

[@OurThrivingLife]

Yes. I totally agree. Although I don’t have crash data, having constructed using both methods the aluminum is much stronger.

[@H2Dwoat]

@@OurThrivingLife hi, thanks for the response.

[@Artmac375]

I wonder if that aluminum would become a spear during the crash

[@H2Dwoat]

@@Artmac375 hi, it’s a compromise either way I believe. The 80/20 is a stronger fixing I think mitigating the risk of it become a projectile but if it does come loose then it is likely more dangerous as a missile. My main reason thinking it is more safe is around securing heavy cargo like batteries but this is why I raised it as I’m not sure which is the best approach.

[@ziasiddique1800]

Not really a comment more of a question. Do you install a vapour barrier on the walls etc?

[@OurThrivingLife]

No. We believe a van needs to breathe. They are not made to be air tight. A good insulation material will moderate the moisture in a van, retaining the moisture when humidity is high and releasing it when the air is drier.

[@bjbhehir]

@@OurThrivingLife when someone asks about vapour barriers you know they've watched too many KZbin videos on van building!! The best thing about 80/20 is you have a lot of area that is open and there's airflow.

[@OurThrivingLife]

Absolutely!

[@mokpixcreativephotoboothvi4725]

Do you ground the aluminum? I only see it done rarely, is it necessary and if so when and where?

[@OurThrivingLife]

We don’t ground the aluminum specifically, but it is bolted to the metal walls of the van, creating a ground.

[@the_real_doktorfisch]

@@OurThrivingLife My concern about bolting the Al directly to the body is the heattransfer in cold conditions. Doesn´t the 8020 get cold, what about condensation on the cold metal? And what about contact corrosion? Other builders put at least a layer of rubber in between or bolt the Alu into wooden beams, that are glued (or screwed) to the sheet metal of the car.

[@MariOdetteKanotz]

@@OurThrivingLife Thanks so much for your reply!

[@OurThrivingLife]

We do put a spacer between the aluminum and the wall of the van. We make these spacers on a 3D printer. When I spoke of a ground, I meant the bolt that goes through the aluminum and into the wall.

[@richardsracingmad]

Do you use loctite blue or red?ok you answered it later in the video!😂 …I’m just filling your Chat for you!😂 lol

[@JulianaAlves-un1tj]

how about foamlite panels?

[@OurThrivingLife]

Haven’t tried those.

[@charlevoix418]

I never understood the idea of building a cabinet using 80/20 then cover it with 19mm birch plywood...

[@minghiy]

Same logic as a concrete building having metal rebar inside.

[@jayteknica1175]

100%, the structural strength comes from the 80/20 box.. 12mm or less plywood would be perfectly fine to finish it out depending on panel span and what’s being stored inside the box.

[@nickh8370]

I can't find the 8020 company you suggested, here in the comments!

[@OurThrivingLife]

The link is under "Extruded Aluminum".

[@nickh8370]

@@OurThrivingLife found it, Thank You!

[@SuckItYouTube19]

You left out 2 other than slot construction benefits... stability and uniformity. Aluminum doesn't swell like wood does. Also, to clarify the STRENGTH point... you get a stronger assembly that takes up LESS space when compared to wood. That makes 3 additional positives.😂😂😂😂

[@OurThrivingLife]

Good points. Thanks for adding to the conversation.