How To Build A Van With 80/20 Aluminum (INSANELY STRONG)

I switched it up in this build and built the entire structure out of 80/20 aluminum extrusions! I'm really happy I did because it is really strong and doesn't squeak or rattle AT ALL while driving. Not to mention, it's pretty lightweight relative to its strength.

Timestamps:
0:00 - 1:07 Overview
1:07 - 2:00 The First Step (Planning)
2:00 - 3:05 What You'll Need (4 parts)
3:05 - 3:35 Floor Tape Mockup
3:35 - 4:00 Tools For Cutting 80/20
4:00 - 5:30 First Day's Progress
5:30 - 7:00 Passenger Side Completed
7:00 - 7:45 Plans For Driver's Side
7:45 - 8:45 Roll-In T Nuts (SO NICE!)
8:45 - 9:15 Driver Side Progress
9:15 - 10:10 I Made A Mistake
10:10 - 11:00 Tip For Heavy Battery Compartment
11:00 - 11:30 Update on Progress So Far
11:30 - 13:30 Methods For Securing 80/20 to The Van
13:30 - 15:55 Mounting Method #1: Plusnuts
15:55 - 18:50 Mounting Method #2: Carriage Bolts & Spacers
18:50 - 19:50 Update After Finishing Mounting
19:50 - 21:20 Pain Of Non-80/20 Aspects
21:20 - 25:50 EVERY SINGLE Mounting Point & Method I Used
25:50 - 28:08 Summary & Outro

[carolinekiley]

I'm 53, building out a van for my husband and myself as we are recent empty nesters. Thanks to you I am thoroughly enjoying the process!!! Showing your mistakes is beyond helpful, and you are skilled at producing an efficient but fun video! I appreciate your attention to detail and work ethic!!! I hope this finds you well !!

[bitman]

I used 8020 to build my camper van, too. Bought some off eBay, some on Amazon, and some from Grainger. For anyone who uses this stuff, recommend buying 8 ft lengths of 1.5 x 1.5 aluminum angle iron, and cut your own right angle connectors. Make a jig, and drill holes in these with a drill press. Also ... I tried the same method of cutting the extrusion with a radial arm saw, but I must of used the wrong type of blade. I got a LOT of aluminum “slag” that “smeared” the cut ends. Had to use a bandsaw instead. Two years later, 20, 000 miles, and hundreds of nights, every joint is still super tight and the just like when it was installed. Expensive, and worth it.

[susangriffis]

Thank you! Someone finally showed how to mount it to the walls and you explained it in depth plus it was NOT in fast mode.

[ThePhiliposophy]

A word of warning to everyone wanting to do the same: Do not use a miter saw designed to cut wood on the 80/20 extrusions. The RPM are too high risking bind up and serious kickback. Yes, it is possible to cut quite a few extrusions, but in the long run it's an accident waiting to happen. Instead use a miter saw with low RPM designed to cut metal and is preferably oil cooled. Unfortunately I am speaking from experience. Did not mean to take away from this awesome video, but add to it. Thanks for sharing your building process!

[isenbergj]

I love using the 80/20 T-Slot aluminum. You were talking about the space saved but look at the weight you cut out as apposed to using a lumber frame.

[gailkellum]

I've been watching Humble Road George's van builds with 80/20 and I love the concept. Very nice video!

[landingentry]

This is gold! Been waiting for you to do this video, my second build is going to be all 80/20!
Thank you for the knowledge and great informative videos!

[RaulMartinez-pqin]

Very nicely done. I’ve been watching tons of videos to get ideas to build my own truck slide in camper. You have some clever solutions.

[outsidedawg]

You need to ground all that aluminum to the chassis. You also need a thermal break so that the heat is not transferred onto the frame of what ever you are building. Installing a rubber washer between the 8020 and the plusnuts might be enough.

[docimma]

Ive watching The Aluminum Carpenter and they have some amazing cutting and carpentry techniques.

[carlshuller]

Okay, I've been watching for months and as of yesterday I have my van. Thanks for all the tips and tricks. I'm in Petaluma so will be hitting you up for local connects. Peace!

[ygreq]

One of the greatest channels on van building IMHO.
I wanted to ask you why you don't use a 1" 8020 frame instead of the 1.5" one. It is smaller so smaller footprint in a tiny space such as a van. Do you think it's not that sturdy?

[maxpower]

I love it. It's clean and strong. I still liked the simplicity of how you build the first van. I'm an old carpenter and you impress me

[davidw]

Hi. Thanks for this advice. Very helpful.
I'm starting in the journey of building my own van. Once I choose the van I will be employing some of you ideas into my van.
I'm in the UK and just wished we could get half the stuff you can at a similar price.
Anyhow, thank you and I will continue to utilise your videos.

[koenverscheure]

I was considering using the 8020 for my van build and I had so much questions... untill now. I think you gave me an answer to almost everything I needed to know to convince myself! Your video came right on time for me ;) Thanks man and good luck with your project!

[katieh]

I love your videos and learning from, younger guys who are knowledgeable in the future
Most men just resort to wood and I haven't learned anything new in years
Thank you

[moneypitvan]

Looks great. There's joy in using 80/20. Once it's bolted to the frame of the van, it feels like it's truly part of the van.

[scottxb]

Amazing video - nicely done. Can't wait to see how you face the 80/20 now! I just ordered my 80/20 for my van. Looking forward to seeing the finished product!

[zachcampbell]

Every video of yours I watch I am becoming a bigger and bigger fan. Thanks for the content brother!

[lucifer]

Bro your material is gold, I'll do a similar project. Thank you for sharing!