DIY Campervan Lining Guide | Plywood, Insulation & Flooring

What materials do you need for a campervan conversion?

Before ordering sheet materials, it is worth deciding what each part of the van needs to do. The materials required for a campervan conversion can vary considerably depending on the layout, vehicle and intended use.

You do not necessarily need to use one plywood thickness throughout the conversion. Selecting the lightest suitable material for each application can help reduce the finished weight of the van.

Planning your campervan sheet materials

Start by making a basic plan of the van interior. Mark out the bed, seating, kitchen, storage, windows, electrical equipment, water system and other major components.

This makes it easier to work out where you need thin wall lining, stronger panels, furniture plywood and a more substantial floor.

It also helps prevent a common conversion mistake: buying large quantities of one thick sheet material and then carrying unnecessary weight throughout the finished vehicle.

Choosing campervan insulation

Campervan insulation is one of the most important materials to plan before the final plywood lining is installed. It can help reduce heat transfer through the van body and make the interior more comfortable in different weather conditions.

The best insulation for a campervan depends on the area being insulated, the depth of the available cavity, the shape of the van and how much interior space you are prepared to sacrifice.

There is no requirement to use exactly the same insulation thickness throughout the entire conversion. Different areas may have very different amounts of available space.

Where is campervan insulation used?

Insulation may be installed in many areas of a van, including:

• Side walls
• Roof and ceiling areas
• Floor areas
• Sliding doors
• Rear doors
• Wheel arch areas
• Behind wall cavities
• Around awkward sections of the van structure

Choosing the thickness of campervan insulation

One of the most important considerations is the space available. A thicker insulation product may be suitable for a deep wall cavity but completely impractical in a shallow door or around a structural rib.

Measure the available space before ordering and consider the final thickness of your plywood lining, battens and any other materials that will sit over the insulation.

Plan your insulation and plywood lining together

Insulation should not be treated as a completely separate stage from the plywood lining. The two systems need to work together.

For example, adding thicker insulation can change the position of battens and therefore the position of the finished plywood. It can also affect wiring routes, fixing points and the amount of usable space inside the vehicle.

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Insulation, condensation and ventilation

Insulation can play an important role in a comfortable campervan conversion, but it is not the only consideration when dealing with moisture.

Sleeping, cooking, washing and simply breathing inside a relatively small enclosed vehicle introduces moisture into the air. If warm, moist air meets a sufficiently cold surface, condensation can occur.

A well-planned conversion should therefore consider:

• Thermal insulation
• Ventilation
• Air movement
• Cold metal areas
• Windows
• Doors and door frames
• Metal ribs and other thermal bridges
• Sources of moisture inside the van

Insulation can help keep internal surfaces warmer, but it does not remove moisture from the air. Ventilation remains an important part of the overall design.

Choosing plywood for campervan walls and ceilings

Plywood is a popular material for campervan wall lining because it is relatively easy to cut, drill, shape and install while providing a clean finished surface.

The correct plywood thickness depends on the size of the panel, how it is supported, the fixing method and what the panel needs to withstand.

These are general starting points rather than engineering specifications. Always consider the actual construction, support and expected loads before selecting the plywood thickness.

What thickness plywood is best for campervan walls?

For many lightweight campervan wall lining projects, 4mm or 6mm plywood can be a sensible starting point.

4mm plywood is particularly useful where keeping weight down is important and the panel has adequate support. 6mm plywood provides additional rigidity and may be preferable for larger panels or areas likely to receive more handling.

Is 4mm plywood suitable for campervan lining?

Yes. 4mm plywood can be suitable for campervan wall lining, ceiling panels, door lining and other lightweight interior applications.

The important consideration is support. Thin plywood should not automatically be treated as structural material. Panel size, fixing points and loading all need to be considered.

If you are specifically looking for thin plywood for a campervan conversion, Plywood Etc stocks a range of sheet materials suitable for different interior applications.

View 4mm plywood →

When should you use 6mm plywood?

6mm plywood provides additional rigidity while remaining considerably lighter than many thicker boards.

It can be considered for:

• Campervan door panels
• Wall lining
• Partitions
• Wheel arch covers
• Shelving
• Furniture backs
• Other interior panels requiring additional rigidity

View 6mm plywood →

Plywood for campervan furniture

Plywood is also widely used for campervan furniture, including cupboards, shelving, drawers, tables, storage boxes, kitchen units and bed structures.

Different components have different requirements, so there is rarely a good reason to automatically use the same thickness for every part of the furniture.

Birch plywood for campervan furniture

Birch plywood is popular for visible campervan furniture because of its clean appearance and attractive exposed plywood edge.

It can work particularly well for:

• Kitchen units
• Cupboards
• Drawers
• Shelving
• Tables
• Storage
• Bed furniture

View Birch plywood →

Lightweight plywood for campervan furniture

Weight can become a major consideration during a van conversion. Lightweight-core plywood can be useful where you want a balance between rigidity, appearance and reduced weight.

Think about the actual job of each component rather than specifying the thickest board available. A cupboard door, shelf and structural bed component may all have very different requirements.

Wheel arches and curved campervan lining

Wheel arches and curved sections are often among the more difficult parts of a van to line neatly.

Before cutting plywood, make a cardboard template. Test fit the template around the curve, mark your fixing positions and then transfer the shape to the plywood.

Thin plywood can be easier to handle in awkward areas, while suitable flexible panels may be useful where there are tighter curves.

Keeping the campervan ceiling lightweight

The ceiling is another area where unnecessary weight can easily be introduced.

A suitably supported thin plywood lining can provide a clean finished surface without adding more weight than necessary.

Before permanently closing the ceiling, plan for:

• Roof vents
• Lighting
• Speakers
• Electrical cables
• Solar wiring
• Access panels
• Roof insulation

Route services and check fixing positions before installing the final ceiling panels.

Campervan flooring and plywood subfloors

The campervan floor has different requirements from wall lining. It needs to cope with foot traffic, furniture loads, storage, bed structures and concentrated loads.

A typical floor construction may include:

1. The original van floor
2. Sound deadening where required
3. Thermal insulation
4. Suitable battens or support where required
5. A plywood subfloor
6. A finished floor covering

The plywood thickness should be selected according to the support underneath it and the expected loads rather than simply choosing the thickest board available.

Do you need marine plywood for a campervan floor?

Not necessarily. Marine plywood is a specialist product and should be selected where its particular specification is required. It does not automatically become the best choice for every campervan application.

The correct plywood should be selected according to the exposure, construction and performance requirements of the particular application.

How to keep a campervan conversion lightweight

Weight is one of the easiest things to overlook when planning a DIY van conversion. Individual components may not seem particularly heavy, but plywood, timber, insulation, flooring, furniture, batteries, water, appliances and equipment can quickly add up.

Rather than asking:

Ask:

That approach can help reduce unnecessary weight while still allowing components that genuinely need additional strength to be built accordingly.

Campervan plywood buying guide

These are general starting points rather than engineering specifications. The correct plywood thickness depends on how the panel is supported, fixed and loaded.

Protect exposed plywood edges

Once your plywood has been cut, pay particular attention to exposed edges and cut-outs, especially in areas where the material may encounter moisture.

Areas worth considering include:

• Floor edges
• Cut-outs
• Kitchen areas
• Sink areas
• Water storage areas
• Door thresholds

Use a suitable coating or sealant for the particular plywood and application.

Plan access before closing the van walls

One of the easiest mistakes to make during a campervan conversion is permanently covering something that later needs to be accessed.

Before installing the final plywood panels, identify electrical components, plumbing connections, heating equipment, inspection points, wiring routes and anything else that may need future servicing.

A neat lining job is useful, but accessibility is equally important once the conversion is in regular use.

DIY campervan conversion checklist

Campervan plywood FAQs