Van conversion walls & ceiling: complete DIY guide

Building your own DIY van conversion in Australia? Our experts are here to help you install your van conversion walls and ceiling.

This article discusses the three most popular van conversion wall ideas in Australia:

• Plywood walls - affordable

• Tongue and groove walls - aesthetic

• Aluminium composite panels (ACP) - practical

We discuss the pros and cons of each material and provide step-by-step instructions (plus a video guide) on how to install your van conversion walls.

We also explain how to use the same material when installing your van conversion ceiling.

Earn up to $10,000 a year by hiring out your campervan - sign up to Camplify today.

Disclaimer: Please use this article as a general guide only and always read the manual for any piece of equipment you use. We recommend consulting a certified professional before beginning any work.

Van conversion walls: ideas and installation

Option 1: Plywood walls

Van example: COKO

Plywood is a great option for your van conversion walls if you want a material that is affordable, readily available and easy to build with. The best thing about plywood is that it is highly pliable and will easily bend to the contours of your van conversion.

We recommend using plywood sheets of about 7mm thickness.

Plywood comes in a variety of types:

• Pine or lauan plywood: Most van conversions use pine or lauan on their walls, as it has a low price point and beautiful grain patterns.

• Cedar plywood: A more expensive option, it looks brilliant and is also mould and mildew resistant. However, it is also harder to source and more fragile than pine or lauan.

• Hardwood plywood: Avoid hardwood, as it is generally heavier, more expensive and less pliable (best used for constructing furniture and cabinetry).

Pros of plywood walls

• Very affordable

• Simple to cut, trim and drill

• Bends easily

• Available in a range of different types

• Stains well

Cons of plywood walls

• Not as attractive as other options

Installing plywood walls in a van conversion

https://www.youtube.com/embed/Bb37KvSLcYs

1. Use self-drilling screws to attach 100 x 25mm pine studs to the metal ribs of the van’s body. This framing is what you will fasten the plywood wall panels to (over the top of your van insulation).

2. Hold a large piece of cardboard up to one section of the wall. Mark the cardboard to create a stencil of the wall.

3. Cut around the cardboard stencil.

4. Test the cardboard template against the wall again, trimming where necessary to get as flush a fit as possible.

5. Once you’re happy with it, trace your template onto a piece of plywood sheeting.

6. Use a jigsaw to cut along the trace on the plywood.

7. To cut out space for your window, puncture four corners into the plywood with a drill bit before joining the holes with a jigsaw.

8. Test fit your plywood - although your template has been trimmed, you’ll probably have to trim your plywood sheeting again to make it a perfect fit.

9. Fix the plywood to the pine stud framing with self-drilling screws (do not pierce the van's external wall).

10. Repeat until all of the van conversion walls are covered with plywood panels.

Option 2. Tongue And Groove Walls

Van example: Sera Couples Getaway

Tongue and groove panels are a great option for your van conversion walls if you are focused on aesthetics. They fill your campervan with character and create a warm and inviting interior. However, tongue and groove walls are more difficult to install in your van conversion than other options.

We recommend using tongue and groove panels of about 7.5 - 9mm thickness. Thinner panelling is lighter, more affordable, takes up less space and can bend to your van’s curved surfaces.

Tongue and groove panels come in a variety of types:

• Pine: The most cost-effective type of tongue and groove panel. They look great and are highly durable.

• Cedar: Slightly more expensive than pine, cedar is beautiful and also resistant to mould and mildew.

Pros of tongue and groove walls

• Looks fantastic

• Available in a range of different types

• If installed correctly, panelling can follow the arc of your van’s curved surfaces

Cons of tongue and groove walls

• Not as easy to install as plywood

• Not as affordable as plywood

Installing tongue and groove walls in a van conversion

1. Use self-drilling screws to attach 100 x 25mm pine studs to the metal ribs of the van’s body. This framing is what you will fasten the tongue and groove wall panels to (over the top of your van insulation).

2. Measure your wall and ceiling dimensions to determine how many panels you’ll need and where to place each one.*

3. Cut your panels with a circular saw. If you need to make more intricate cuts and trims, use a handheld jigsaw.

4. Beginning at what will be the bottom row, get one person to hold a panel in place while the other drills it into the pine stud framing with self-drilling screws (do not pierce the van's external wall).**

5. Position subsequent panelling with the help of the tongue and groove of each board.

6. Repeat until all of the van conversion walls are covered with tongue and groove panels.

* Pro tip: Plan your cuts carefully so that the end of every board is positioned near a pine stud or metal rib for smooth attachment.

** Pro tip: Don’t place a screw too near a board’s end or it could split.

Option 3: Aluminium composite panels (ACP)

Van example: Yugen II on Camplify Australia

Aluminium composite panels (ACP) are a great option for your van conversion walls if you want a material that is modern and practical. It’s available in a wide array of colours and has a nice glossy finish to it.

The best thing about ACP is that it is highly durable, waterproof, easy to clean and impenetrable to stains. It is also fairly flexible and will bend nicely to the contour of the walls of your campervan.

However, it does weigh slightly more than plywood or tongue and groove panels. Also, you’ll likely need an assistant to help you pick it up and hold it in place.

Pros of ACP walls

• Durable, waterproof and stain-resistant

• Simple to cut, trim and drill

• Easy to clean

• Fairly flexible

• Insulated

• Available in a range of different colours

• Modern aesthetic

Cons of ACP walls

• More expensive than timber options

• Weighs more than timber options

Installing ACP walls in a van conversion

1. Use self-drilling screws to attach 100 x 25mm pine studs to the metal ribs of the van’s body. This framing is what you will fasten the ACP wall panels to (over the top of your van insulation).

2. Hold a large piece of cardboard up to one section of the wall. Mark the cardboard to create a stencil of the wall.

3. Cut around the cardboard stencil.

4. Test the cardboard template against the wall, trimming where necessary to get as flush a fit as possible.*

5. Trace around the cardboard template onto a sheet of ACP. Leave the protective film on the ACP to prevent scratching.

6. Use a jigsaw or circular saw to cut along the trace on the ACP.

7. Drill through the ACP where you want to insert screws for attaching it to the framing.

8. Use fascia screws or sheet metal screws to attach the ACP to the wall framing.

9. Repeat until all of the van conversion walls are covered with ACP.

10. Remove the protective film from the ACP.

Pro tip: Ensure that you have plywood framing behind each cardboard template. Add more framing if necessary.

Van conversion ceiling: installation

Van example: Cruisingwithvan on Camplify

All of the above materials (plywood, tongue and groove and ACP) can also be used on your van conversion ceiling. However, the installation method is slightly different.

1. Before installing your van conversion ceiling

Before you install your van conversion ceiling, you’ll need to complete a few crucial steps:

• Insulate your van

• Install van ventilation

• Cut holes for LED lighting and wiring:

• When you reach the row of panels that will hold the lighting, mark exactly where each light will be positioned.

• Take the board down and use a drill and hole saw to cut holes for the lights.

• After installing all the other ceiling panels, screw this centre board into place and feed the wiring through each respective hole.

2. Framing your van conversion ceiling

Use self-drilling screws to attach 100 x 25mm pine studs into the metal ribs of the van’s ceiling. This framing is what you will fasten the ceiling panels to.

If you plan on installing the ceiling panels lengthways (i.e. front to back), you should install the framing sideways (i.e. from side to side). Alternatively, if you plan on installing the ceiling panels sideways, you should install the framing lengthways.

3. Optional - paint or stain the ceiling panels

If you want to use plywood or tongue and groove panels on your van conversion ceiling, you may want to paint or stain them to differ from the walls.

4. Installing the ceiling panels

Once the framing is up, screw the panels in to place one row at a time using self-drilling screws (for timber) or sheet metal screws (for ACP).

Switching between the driver’s side and passenger’s side as you go. The aim is to have both sides meet in the middle, so make sure to measure this out beforehand.

Don’t panic if you find that your two sides are meeting at an angle. It just means you’ll just have to cut the centre panel to fit between them. Trace the shape of the gap by holding a board up to it and marking the angle. Then cut along this trace with a jigsaw, testing and trimming to make it slot in seamlessly.

Make money from your van conversion

Now that you’ve installed your van conversion walls and ceiling, you’re almost ready to complete your campervan build and hit the road!

But what about those times when you’re not travelling? Don’t let your campervan sit idly in the driveway…

Make money from your van conversion by hiring it out through Camplify!

Camplify makes it easy for van owners to earn income from campervan hire in Australia.

Why Camplify?

Each year, heaps of Aussies earn up to $10,000 by hiring out their campervan through Camplify. It provides a quick and easy way to generate long-term passive income and earn a return on their investment.

And the best part is that Camplify takes care of many of the expenses involved in hiring out your vehicle, including:

• Comprehensive hire insurance.

• 24/7 NRMA nationwide breakdown cover for hirers.

• Dedicated customer support.

If you’re interested in joining Camplify as an owner, try our earnings calculator and see how much income you could generate each year by renting out your unused campervan!