The top 5 van build mistakes

By Cheri Sicard
Building a van is an exciting adventure. But it’s easy to stumble along the way. Jeff and Lisa Warnick of Thrivans have seen it all. They’re here to help DIYers (and even some professional builders) dodge common pitfalls. Avoiding these mistakes can save serious time, money, and future headaches.

Mistake #1: Overdoing insulation

Insulation is a hot topic in the van-building world. There are endless options and opinions. It’s easy to get lost in the details. Researching insulation can feel like falling down a rabbit hole. There’s so much information to digest. Different materials, R-values, and techniques can be overwhelming. Where do you even start?

It’s tempting to pack every nook and cranny with insulation. But here’s the truth: You can’t insulate everything in a van. There will always be areas where heat escapes or enters.  Windows are the biggest culprit when it comes to thermal transfer. They’re responsible for most of the heat loss in winter and heat gain in summer. Even with window covers, windows remain a weak spot in your insulation strategy.

The floor is a major source of cold (and sometimes heat). Insulating it properly is essential for comfort. Don’t go overboard, though. Excessive floor insulation can reduce headroom. Nobody wants to feel cramped in their van.

Many DIYers cover the entire floor with sound-deadening material like Kilmat. While it can reduce noise, it has minimal insulation value. Covering the entire floor is unnecessary for sound deadening. It adds extra weight, expense, and time to your van build.

There are many insulation choices available.

• Spray-in insulation is effective but contains chemicals and is more expensive.
• 3M™ Thinsulate™ and Havelock Wool are great insulators. Do your own research to find the best fit for your needs.

Mistake #2: Not getting things square or plumb

Achieving perfect squareness and plumbness in a van is tricky. Vans aren’t perfectly shaped. They have curves, tapers, and uneven surfaces. The walls taper, the roof curves, and the floor may be uneven. These imperfections make it challenging to build perfectly square and plumb structures.

Misaligned cabinetry is a common problem. Upper cabinets might be angled or tilted. These imperfections can be visually jarring. They can also affect the functionality of your living space.

Squareness and plumbness are essential in construction. They ensure structural integrity and visual appeal. Traditional tools like levels and plumb bobs don’t always work in a van. This is due to the van’s irregular shape. Here are some tips to help you achieve alignment in your van build.

• Find the center line: Find and mark the center line of the van. Use a laser or reference points on the floor. Measure from the center line rather than the walls. This will help you create straight and symmetrical structures. Also, mark a center line on the ceiling. This will help you align ceiling strips.
• Use a digital level: A digital level can be calibrated to a new “zero” point. This allows you to establish a reference point. Use it to ensure parallelism with the floor. You can also use it for exterior items like running boards. Set the digital level on the step to make the running board parallel.

Mistake #3: Using the wrong materials

Using the right materials is crucial for a long-lasting van build. Use marine-grade products whenever possible. Marine-grade products are high in quality and durable. They ensure safety, even though they cost a bit more. Use marine-grade or RV-grade components for lighting, switches, and electrical systems as non-rated components aren’t designed for this type of application. This can lead to potential safety issues.

Many DIYers use MDF or particleboard because they are readily available and easy to paint. However, these materials have serious drawbacks.

• Durability issues: MDF and particleboard aren’t very durable. They absorb moisture, causing expansion, bowing, and bubbling. MDF is also dense and heavy.
• Fastener issues: These materials don’t hold screws well. Vibration can loosen screws and cause material failure. Think of IKEA furniture. It looks great at first. But it can easily break if you move it.

Choosing the right fasteners is also important.

• Avoid nails: Vibration can loosen nails. Also, you need accessibility to remove and replace components easily.
• Use stainless steel fasteners: Stainless steel is stronger and more resistant to moisture.

The right adhesive can also make a big difference.

• Wood glue: Use wood glue in addition to screws for stronger, squeak-free cabinetry.
• Marine-grade adhesive: Always use marine-grade adhesive for adhering items to the van. Loctite marine adhesive is a great option. Construction adhesive lacks flexibility. This leads to cracks and squeaks.

Mistake #4: Forgetting accessibility

Plan for accessibility from the start. You need access to components like electrical and plumbing systems. You should be able to remove and replace things easily. Install doors and hatches in necessary locations. This provides access to hidden components.  Remember to use screws instead of nails. Nails are difficult to remove to gain access.

Mistake #5: Electrical issues

Electrical issues are the most common problem in van builds. Component quality is key. Use high-quality, marine-grade electrical components.

• Blue Sea Systems is a reliable choice. It may cost more. But it’s worth it for the reliability.
• Use high-quality products from Victron. Renogy is a more budget-friendly option. Victron offers quality, customer support, and seamless integration.
• Use high-quality, UL-listed batteries.

Wiring and connections

• Poor connections: Use marine-grade connectors.
• Wire protection: Protect wiring from metal edges. Use loom, zip ties, and clamps. Use rubber trim edging on metal edges.

Bonus tip: Don’t rush the big steps

Think about accessibility. It’s tempting to complete big steps quickly. This gives a sense of accomplishment. But it can create problems later.

Many want to use their van before it’s fully finished. Installing electrical components or walls before wiring can hinder the build and make it difficult to access the components should you need to.

Building a van is a rewarding experience. By avoiding these common mistakes, you can save time, money, and frustration. Plan carefully, use quality materials, and prioritize accessibility. Your dream van will be a reality.

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