Wall Battening + Insulation (and general update!) | Fiat Ducato | UK Self-Build Campervan Conversion

It's been a bit of a while since we posted a video, sorry about that! Lots has happened on the van and also more generally. I got a new job in May and that has taken most of my brain power and energy recently. But we're now back to full steam on the van so that we can start using it as soon as possible (in fact, we're using it for the first time in a few weeks!!!)
This video is about our wall framing and insulation. We'll talk through our thought process, what we decided to do, how we did it and some of the techniques we used (including pocket hole joints and rivnuts). The build is now less structured as we're doing bits on the ceiling one day, the floor the next and the bed after that! So we'll try and continue to have a subject per video but we may eventually come on to more general updates.
Let us know what you think in the comments or with a thumbs up and see you soon!
Mark & Neil
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Products Used
Makita Combi Drill & Impact Driver: amzn.to/3wwzJ0B
Clamps: amzn.to/3vkwlFq
Rivnut Tool: amzn.to/3wCO8au
Pocket Hole Jig: amzn.to/3xyCY7P
Pocket Hole Screws: amzn.to/36uPp8U
Zinnser Primer: amzn.to/3r4y8g8
Vapour Barrier: amzn.to/36sAmwm
Play-doh: amzn.to/3htBBls
Timings
00:00 Intro
07:08 How to fix the battens
12:18 Pre-drilling the wood
17:26 Insulating the walls
22:25 Pocket hole joints
26:30 Upright battens
37:33 Final steps and wrap up
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WHO ARE WE?
We're Mark and Neil and this is Our Van Plan. We've always wanted a camper van and took the plunge in 2020 by ordering a brand new medium wheelbase (L2H2) Fiat Ducato. We are converting it ourselves into the van of our dreams with little previous experience. We're glad to have you along for the ride!
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FOLLOW US
You can follow our build in real time over on Instagram....
/ ourvanplan
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#ukvanconversion #vanlife #campervan #ducatocampervan

[@angus9541]

This is probably one of the most informative videos on this subject. I’ll be taking a lot from here. Thank. Many headaches quashed

[@OurVanPlan]

Really glad you found it helpful 👍

[@RburtonJ86]

You are a gem! I've been looking for a video faaaaar too long about how to get around the columns/pillars that stick out in Boxers/Ducatos and finally its been discussed! Dont know why other Ducato/Boxer youtubers never properly discussed it and show how to do it. Thank you! Additionally you communicate very clearly and to the point which makes watching and learning a lot easier. I wish I came across your channel weeks ago

[@OurVanPlan]

Ah thank you, means a lot. Glad you found the video useful. Tried to show all the decisions/challenges and how to overcome. Looking back the Ducato is definitely the more straight forward of all the panel vans to do. Tho it didn’t feel like it at the time 😂

[@malcolmwhyte5856]

Very well presented with lots of useful information. I am buying a boxer for conversion in the next two weeks. I have no experience of builds / conversions so these videos are invaluable to people like me. Very detailed with great explanations. Keep up the good work.

[@OurVanPlan]

Thanks Malcolm. Good luck with your build. It’s such a rewarding process (eventually 😂)

[@jasonfarrell5857]

riff nuts are a great idea - love the videos guys

[@stevesimpson5417]

Such useful and inspiring videos for me just starting out, I have the Citroen L2H2. I've watched this one several times now, so very helpful. Can't wait to see the rest of the build. Particularly the electrics and plumbing

[@OurVanPlan]

Thanks Steve, glad they’re of use to you. I’m currently messing around with water tanks so the plumbing video shouldn’t be too far away (bit behind on the editing!)

[@sebastienvanmelick1668]

Great job! I’m watching you from Belgium and really keen to see what’s coming after. I’m busy building a Fiat Ducato as well and so far, you have been really helpful 👍

[@OurVanPlan]

Great to have you along and glad you’re finding it useful. We love the Ducato - great van.

[@CampervanTales]

Just found your channel. Great to see another couple of blokes doing their own conversion. Now subscribed to you

[@OurVanPlan]

Glad to have you along! Thanks for subscribing 😊

[@CasLaz]

It's coming along nicely! Battens / insulation / wiring took forever for us too, look forward to how you get on with the rest of the build!

[@OurVanPlan]

Thanks. Yeah it feels like a never ending stage! But moving forward now and it’s starting to feel like a campervan!

[@Poontang123]

You can make an inprint on the wood battons by using a rubber mallet to stike while its held over the riv nuts

[@julianowens4071]

Very nice job

[@OurVanPlan]

Thanks 🙏

[@errolmagill1611]

I have been following your progress and I must say yous are doing brilliant - all the more impressive considering this is your first go at this kind of thing; I am sure you said you had no DIY experience, so obviously have been studying the theory of van conversions. Glad to see you using rivnuts; if ever you are in a collision you will not want stuff coming loose and into the back of your head, not every van converter considers this. Great selection of tools and equipment too.

[@OurVanPlan]

Thank you. Really appreciate your comments Errol. Reading things like this keep us going 👍🏻 we definitely have almost zero DIY skills but have learned so much already! Trying to do the best we can means a slow build but good things come to those who wait 😊 cheers!

[@brianscothern2569]

Great. I been trying to work out the wall problem myself. You done it for me. Thanks. BS/

[@OurVanPlan]

Haha I’m sure there are better ways. It’s difficult but we found it’s always easy to adapt as you go if you forgot something or need something in a different place!

[@roberthampton7651]

@@OurVanPlan i have a ducato too and the two pillars are causing my problems...being thicker than the other parts :-(

[@paulmoir275]

Great videos guys and super work. Is there a video to come with the ply wall fit and more interestingly the scary templating?

[@cartes5996]

Just started watching your van build very informative. Question what material rivnuts and bolts did you use as the van is galvanised.

[@adamshah2713]

Thanks for the informative video!! I was just wondering if you remember the length and width of the main van panels you put the PIR board over?

[@OurVanPlan]

Thanks glad you found it useful. I can’t remember to be honest but I think there are plans online you could calculate it from.

[@timbartholomew2095]

Thanks for the video its really helpful. I was wondering if the Webastol heater that you got as a factory add on is sufficient as a heating system for the van ?

[@peapod2083]

Tim, I asked this question on another video and it is 😀

[@cashmr2001]

A real joy to watch, very informative and detailed. One question, what are the pins called you are using a 20:05, apparently for keeping up the insulation?

[@OurVanPlan]

Thank you. I think they’re just called insulation pins or something like that. You can get them from most DIY places.

[@lesvoyagesdelouis6574]

Joli

[@gavincooke8808]

Hi, where did you get the plusnuts from please? Thanks for the videos, very detailed and useful!

[@OurVanPlan]

Thanks. I ordered them on eBay in the end.

[@Campervan-Dreams]

Hi, I'm really enjoying your Videos thanks. Watched this one twice now & hope you're enjoying the use of the van. I'm sure I'll get around to watching the trips too. What vapour barrier did you use please/where from and I assume there's an air gap between the ply & that? Be really useful to know please 🙂

[@OurVanPlan]

Thanks glad you’re enjoying the videos. It was foil vapour barrier from Amazon. Whether it actually does anything I don’t know! Yeah there would be a natural air gap but not an engineered/deliberate one.

[@Campervan-Dreams]

@@OurVanPlan Many thanks

[@debcamper4608]

Hey, Hope your loving life with your van. I’m at the bed stage now and watching your videos which are brilliant. You call the battons “ the big piece of wood” but don’t mention the size. I know the length which you mentioned but can you tell me the size of the piece you used? Thank you Deb

[@OurVanPlan]

Do you mean the bed slats? They’re 70mm x 18mm.

[@debcamper4608]

Hi, I’ve got the same van. How much sound deadening and insulation will i need to buy. Loving watching your build X

[@OurVanPlan]

I used 1 bulk pack of the Silent Coat sound deadening mats/steets. I’d say I’ve used 2 rolls of the plastic bottle insulation and then 1 x 50mm and 2 or 3 x 25mm kingspan sheets. Hope that helps?

[@debcamper4608]

@@OurVanPlan Thanks so much for your reply. You’ll probably be hearing from me again. I start my build 10th June 🥴🥰

[@steved2189]

Where did you get the facia for the gap thats left on the overcab bit !! When you removed the metal bulk head

[@OurVanPlan]

We ordered the van new and specified bulkhead deletion. So there wasn’t ever a bulkhead and the factory fits the plastic trim instead.

[@vladimirmartinov7282]

how long is the living area ?

[@debcamper4608]

Hey, could i also ask where you got your bed aluminium frame from. Thanks so much.

[@OurVanPlan]

Yeah we got them from RS components.

[@euanmcgill918]

What were you painting the battens with?

[@OurVanPlan]

Zinnser Primer. Basically protects them against mould and damp and stuff. Arguably unnecessary but we went belt and braces!

[@euanmcgill918]

@@OurVanPlan ah great, I'll add it to the might do list 😁 really enjoying the videos, gradually working my way through them, making notes

[@katyd4183]

Im windering what the blue is...

[@katyd4183]

What is the blue stain in the battens?

[@OurVanPlan]

It’s rot protection but they come like that from the shop

[@martynlawrence2365]

Please don't take this as critism but you seem to making a great deal of extra work for yourself. Why not use automotive bonding instead of nuts and bolts? Lots of insulation but pillars left hollow which defeats the object. Panels could have been bonded in place using spray foam (insulation and fixing all in one). Don't forget all the extra weight you are adding as the van is rated at or around just 1x ton.

[@MikeBaxterABC]

25:55 But it's all split open!! That's no good :(

[@davidbailey4533]

A bit slow and drawn out.

[@OurVanPlan]

Yeah the battening phase is quite tedious but probably the most important part of the build to get right!

[@leelendon1482]

Hi Mark and Niell .well I'm onto wall battens now and it's testing me lol. Like rhe method tou have used to get straight lines without compromising space . Im too using the kingspan 50mm and 25mm to pack out the space behind the battens . One question are all your battens 25mm . Also the upper cabinet area where you have put blocks of wood over the hollow areas are these thicker ? Many thanks for the video it's helping me out alot . Regards Lee

[@OurVanPlan]

If I can remember I think the uprights are 18mm and the horizontal blue ones are 25mm. The ones on the angled bit at the very top were bigger blocks I think 38mm thick. This levels with the posts in the middle of the van. Glad you’re finding the video useful and good luck with your build.