Recreational Vans
Aluminum extrusions are precision profiles pushed through a die to create repeatable shapes. The most common for builders are T slot profiles often grouped under the 8020 name. Grooves along each face accept specialized nuts and connectors, which lets you assemble rigid frames with simple tools. Think of it as adult scale construction blocks with engineering level tolerances.
Because aluminum has a high strength to weight ratio and natural corrosion resistance, these profiles are ideal in mobile environments. You can cut them on a miter saw with a non ferrous blade, drill them accurately, and add panels, hardware, or accessories at any point along the slot. The system is modular by design, so you can iterate layouts without starting over.
Common sizes include 15 series and 10 series in imperial, or 40 series and 30 series in metric. The larger the section, the higher the moment of inertia and the better it resists bending. Corner braces, inside corner connectors, and joining plates create simple square frames. Hidden anchors and pivot joints support doors, slides, and adjustable features. The catalog of parts is deep, which makes 8020 an adaptable backbone for cabinetry, beds, bulkheads, and gear mounts.
Before you cut a single profile, map load paths. In a moving vehicle, forces come from acceleration, braking, cornering, potholes, and vibration. Your aluminum extrusions frame should route loads to factory tie downs or a reinforced floor and walls. Continuous rails distribute stress better than isolated brackets. When possible, align profiles with vehicle ribs or smart floors designed for point loads.
Deflection matters more than ultimate strength. A frame that barely bends keeps latches aligned, drawers smooth, and panels quiet. Use shorter unsupported spans, gusset the corners, and choose profiles with higher section modulus where you need stiffness. Cross bracing triangles are your friend. A small diagonal can dramatically reduce racking in a tall cabinet.
Fastener selection determines performance. Roll in or drop in T nuts allow post assembly changes, while pre load anchors and double anchors increase clamping force. Stainless hardware with anti seize prevents galling. Nylon insert locknuts resist vibration. For joints that need to stay invisible, consider hidden corner connectors and tapped ends with thread locker.
Panels bring the structure to life. Lightweight composite or marine plywood attached with button head screws and finish washers spreads load and adds shear strength. Use thin closed cell foam tape between panel and extrusion to prevent squeaks. For doors and drawers, full extension slides mount cleanly to the slot, while hinges with adjustable offset help achieve even reveals. Edge trim and gaskets keep dust and rattles out on dirt roads.
Two sounds dominate poorly designed frames. The first is panel buzz from resonance. Break up large panel spans with intermediate supports and use damping layers like butyl or acoustic foam where practical. The second is metal on metal chatter. Isolate contact points with nylon shims and tape. Torque hardware consistently so joints do not micro move.
8020 aluminum extrusions save weight compared to heavy lumber when designed correctly. Keep mass low and centered. Place water, batteries, and dense storage forward of the rear axle when possible. A lighter, stiffer frame improves handling, reduces tire wear, and keeps doors aligned over time.
Treat your frame like a safety component. Use thread locker where required, torque to spec, and mark fasteners with paint pens to spot movement later. Plan access panels for inspection of wiring and plumbing. The benefit of 8020 is serviceability. You can remove a single bay, add a brace, or reroute a cable without tearing the whole interior apart.
Think in layers. Start with the base frame bolted to a reinforced subfloor. Add verticals with corner braces. Tie the structure to the wall with isolation mounts so you do not telegraph body flex into the cabinetry. Cap the build with overhead runs that land into the uprights, not just the van skin. Every joint should do a job.
For hardware, consider adjustable feet, L plates, pivot joints, linear rails, and threaded inserts for accessories. To support a bed, spread the load with transverse beams and a slatted deck to avoid moisture buildup under a mattress. For galley units, mount slides to vertical members and use anti tip catches. For bike and gear storage, integrate track mounts and cam straps anchored to the frame.
Corrosion management is straightforward. Aluminum resists rust, but dissimilar metal contact can create galvanic issues. Use stainless or zinc plated fasteners with isolation washers. Seal raw cuts with clear coat. If you powder coat panels or use anodized profiles, you gain scratch resistance and a refined look. Where profiles meet exterior moisture, add gaskets and drip management.
Electrical and plumbing integration should be designed in, not added later. Leave wire ways inside profiles or use cable carriers along the slot for clean service loops. Mount bus bars, inverters, and fuse panels to dedicated plates attached to the frame. For water lines, clip PEX to the structure with cushion clamps and provide strain relief at fixtures. Service loops and labeled runs save hours down the road.
Before finishing, load test shelves and beds with real weight. Drive a rough route to listen for movement. Retorque after the first shakedown. A careful test cycle turns a good 8020 build into a great one.
The best results often blend 8020 with wood, composites, and custom metalwork. Use extrusions for the skeleton, marine plywood for skins, and aluminum sheet for wear plates. Add CNC cut details where precision matters. Each material plays to its strengths.
Profiles are reusable and recyclable. Offcuts become brackets. The modular nature reduces waste compared to one time carpentry. Choose reputable suppliers with consistent tolerances, and consider anodized finishes for durability without paint.
A well executed 8020 interior feels solid, looks clean, and works quietly at highway speed. The frame creates a true reference plane so doors line up, drawers glide smoothly, and gear remains locked down. Panels and trim add warmth without sacrificing service access. Most important, the structure supports daily use, from wet boots to heavy tools to a week of washboard roads.
If you prefer a finished, road proven result built by specialists, OZK Customs designs, fabricates, and installs aluminum extrusions frameworks, cabinetry, mounts, and integrations inside complete custom van builds and overland upfits. Our team handles structural design, precise machining, final fit, and the small details that keep a mobile interior quiet and durable.
We build in Fayetteville Arkansas and deliver nationwide. Clients can pick up, get a full systems walk through, and head straight to the trails from our shop. Whether you need a family friendly layout, moto friendly storage, or a compact remote work bay, we translate goals into a clean 8020 structure that stands up to real travel.
Strong frames, smart fasteners, quiet panels, and tidy wiring. That is the formula for 8020 that lasts on the road. When you are ready to turn these principles into a finished van or overland rig, we are here to build.
Ready to turn a smart 8020 concept into a road proven build that looks clean, rides quiet, and lasts. Tell us how you travel and we will design, fabricate, and install a complete solution. Submit the form to start your custom van or overland upfit with OZK Customs. Our services include complete custom builds and partial upfits across recreational vans and overland rigs, plus custom fabrication and integration for power, water, storage, racks, lighting, and connectivity.
Ready to turn a smart 8020 concept into a road proven build that looks clean, rides quiet, and lasts. Tell us how you travel and we will design, fabricate, and install a complete solution. Submit the form to start your custom van or overland upfit with OZK Customs.
ADDRESS:
6159 E Huntsville Rd, Fayetteville, AR 72701
PHONE:
(479) 326-9200
EMAIL:
info@ozkvans.com