Cabinetry Materials for a Van Conversion

Tips on lightweight materials and construction for a mini-motorhome buildout. December 28, 2005

Do you have any suggestions for the overall conversion of this B-Class Sprinter Van? What lightweight, rigid material should I use for box construction, doors, etc.? What lightweight countertop choice for damage resistant surfaces? The weight factor of any or all materials used is of significant importance.

Forum Responses
(Cabinetmaking Forum)
Kydex is a good product for your application.

One product is Ultralight from Moreland Company. Although it's not on their website, they also have a product called "BalsaPly." And as the name implies, it has a balsa wood core.

Much of the cabinetry in motor homes is 1/4" or even 1/8" panels overlaying a frame of 1/2" or 3/4" pine, along the lines of a hollow core door. Thinner products are used throughout as well. Countertops are occasionally hollow, but typically 3/4". I think the "thump" factor is an issue for manufacturers. People perceive the hollow sound as cheap, (and they might be right!). Might want to stroll around a motor home lot to get ideas.