Fastening Panels to 8020 Modules in your DIY Van Build

Fastening Panels to 8020 Modules Intro

Building your van galley modules out of extruded aluminum (8020) is a smart choice to keep your van build lightweight, strong, and long-lasting. But, although there are many benefits to using 8020, it does make paneling more difficult than traditional wood construction where you can simply nail and screw things together. How to fasten panels to 8020 is a common question we receive on Instagram. Thankfully, after two conversion van builds, we have tried many different techniques, and are happy to share with you the two best options depending on your visual preference. Enjoy!

A note on products: 8020.net makes all the hardware you need for your van building needs, and we have partnered with them to bring a discount to DIY van builders! By clicking through any link on this page, a 5% discount will be applied to your cart.

** Disclaimer: This post contains various affiliate links that provide a small kickback to us. We truly appreciate if you choose to purchase through them as it allows us to keep providing our content for free. Thank you! **

2 Methods for Fastening Panels to 8020

While you may stumble upon other methods for fastening panels to your 8020 modules, we believe the two methods below are the simplest, and cleanest. The first method results in inset panels so you will see the 8020 profile. While the second method results in overlayed panels, hiding the 8020 profiles. Choose wisely! (Just kidding, we actually have both methods in our latest build and love each for different reasons).

Method 1: Inset Panels

8020 has designed specific panel brackets (retainers) for fastening panels to 8020 profiles as inset panels. These panel brackets have a standard bolt hole on one side, and a threaded hole on the other end [hardware list below]. The bolt hole side is for attaching the bracket to your profile with a bolt and t-nut. While, the threaded bolt hole is for attaching to your panel. In order to achieve perfect inset panels, you should cut your panel 1/16″ to 1/8″ inch smaller than your X-Y opening. The tighter the better, of course, but with wood, you also want to keep in mind that it will expand so somewhere in the above range should be good.

To install inset panels, measure where your panel brackets are, and drill holes through your panel in the appropriate location. Additionally, for a clean and finished look, use a countersink drill bit to recess your bolt head into the panel. Your bolt hole size can be 1/16″ of an inch larger than your bolt size.

Hardware and Tools Needed

The hardware and tools list below will result in this assebly:

Below we will break down hardware needed for each 10 series, and 15 series 8020. These are the two most common profile types used in DIY Van Building, and you can read about the differences in our Guide to Van Building with 8020.

10 Series Hardware & Tools Needed

10 series Single Arm Narrow Panel Retainer Bracket
1/4-20 Roll in T nut (1 per bracket)
1/4-20 .5″ FBHSCS (1 per bracket)
1/4-20 .75″ counter sunk bolt (1 per bracket) Note: Counter sunk bolt length might need to be adjusted with thicker panels!
1/2″ Counter Sunk Drill Bit (set linked or get single at local Ace)
5/16″ Cobalt Drill Bit (for countersunk bolt holes)
5/32 Allen Wrench ball driver

If you don’t want to use counter sunk bolts, simply purchase an additional standard 1/4-20 bolt of length > width of panel material + 1/4″.

15 Series Hardware & Tools Needed

15 series Single Arm Narrow Panel Retainer Bracket
5-16/18 Roll in T nut (1 per bracket)
5-16/18 .687″ FBHSCS (1 per bracket)
5-16/18 1′ counter sunk bolt (1 per bracket) Note: Counter sunk bolt length might need to be adjusted with thicker panels!
5/8″ Counter Sunk Drill Bit (set linked or get single at local Ace)
3/8″ Cobalt Drill Bit (for countersunk bolt holes)
3/16 Allen Wrench ball driver

If you don’t want to use counter sunk bolts, simply purchase an additional standard 5/16-18 bolt of length > width of panel material + 3/8″.

Method 2: Overlay Panels

If you want to hide your 8020 profile, you can oversize your side panels, cover the 8020 pieces, and use standard 2 hole corner brackets so that the panel sits flush against your profile. Align and drill the holes in the panel the same way as described above and use a counter sink bolt / nylock nut combo to fasten the panel to the corner bracket. Additionally, routing the outer edges of the panel can give a clean and finished look (see photos).

For this option, you of course want to size your panel to go from end to end of the profiles, not the inner section.

Hardware and Tools Needed

The hardware and tools list below will result in this assembly:

10 Series Hardware & Tools Needed

10 series 2 Hole Inside Corner Bracket
1/4-20 Roll in T nut (1 per bracket)
1/4-20 .5″ FBHSCS (1 per bracket)
1/4-20 counter sunk bolt (1 per bracket) Length should be thickness of panel + 1/2″
1/4-20 Nylock Nut (1 per bracket)
1/2″ Counter Sunk Drill Bit (set linked or get single at local Ace)
5/16″ Cobalt Drill Bit (for countersunk bolt holes)
5/32 Allen Wrench ball driver

15 Series Hardware & Tools Needed

15 series 2 Hole Inside Corner Bracket
5-16/18 Roll in T nut (1 per bracket)
5-16/18 .687″ FBHSCS (1 per bracket)
5/16-18 counter sunk bolt (1 per bracket) Length should be thickness of panel + 5/8″
5/16-18 Nylock Nut (1 per bracket)
5/8″ Counter Sunk Drill Bit (set linked or get single at local Ace)
3/8″ Cobalt Drill Bit (for countersunk bolt holes)
3/16 Allen Wrench ball driver

How many panel brackets do you need?

How many panel brackets to use is partly up to user discretion. Generally, you will need more panel brackets for larger and thinner panels, and fewer for smaller and thicker panels. For reference, we use 4 for our larger galley panels, and 3 for smaller side panels.

Panel Size and Material Type

Panel material selection for your camper van modules is dependent on application, and design preference. For example, you may encase your van electrical system with polycarbonate sheet, but you may want to use veneer or painted plywood for your main kitchen galley. Either decision will result in the same panel attachment options described above.

Standard plywood thicknesses are 1/4 – 1/2” for camper van applications. Polycarbonate / Composite finishes are generally 1/8”-1/4”. Use 1/2” plywood for larger panels where you need rigidity, or where you will be mounting other accessories. Use 1/4” for smaller pieces where it is good to save on weight and cost! This is also a good place to mention that if a side of your galley is not seen, you do not need to add a panel; the weight savings, and the airflow through your van is well needed.

DIY Van Building With 8020 Resources

We have built two campervan conversions completely with extruded aluminum and could not recommend it more if you want a strong, sleek, lightweight van build. If you found yourself on this page, you might enjoy some of our other extruded aluminum building resources: