Comparison ·Dec 04, 2025

Choosing Your Canvas: A Deep Dive into Van Wall Kit Materials

Hey everybody, Matt here for AVC, and welcome back to the blog!

The introduction of our paper patterns for wall kits has brought up a great question: What material should you actually use to build your walls?

The right choice depends on your budget, your final aesthetic, and how you plan to use your van. Let's look at the essential qualities to consider and break down the pros and cons of the most common materials, including our newest, ultra-lightweight option.

Key Qualities to Consider in a Wall Material

Choosing the right substrate for your walls isn't just about what looks good; it's about engineering a safe and durable space.

⚖️ Weight: Excessive weight impacts fuel economy, handling, and your overall payload capacity. Since you're often covering the walls, avoid overly heavy, burly materials.
💧 Resistance to Moisture: Are you in a humid climate or planning an interior shower? Materials must be stable and resistant to warping, swelling, or degrading when exposed to moisture.
🔩 Screw Retention: Will you attach cabinets, gear, or accessories directly to your walls? If so, you need a strong material that can hold screws firmly, especially on bumpy roads.
🌡️ Flexibility & Warping: The van's interior is not flat. The material needs enough flexibility to conform to the contours but must be stable enough not to expand, contract, or warp with extreme temperature changes (like plastics often do).
✨ Appearance: If you're wrapping the material in fabric, its raw appearance is less important. If you plan to clear-coat or leave the material exposed, the natural finish (like with Baltic Birch or Max Metal) becomes a primary factor.
💰 Cost: Van builds are expensive. Selecting a lighter, more cost-effective material can save money without sacrificing necessary performance, especially if you plan to cover it completely.

Wall Kit Material Options

Here are the most common materials used in professional and DIY van conversions, including our newer felt option.

1. The Industry Standard: Baltic Birch Plywood

Quality	Assessment	Notes
Stability	Excellent	Very strong and stable in large sheets.
Moisture	Very Good	Manufactured with exterior-grade glue, highly moisture-resistant.
Screw Retention	Excellent	Best option for securely mounting heavy accessories.
Cost	High	The most expensive wood option.
Finish	Premium	Can be clear-coated for a beautiful, raw wood look.
Use	High-end, where strength is paramount.	The industry go-to for a premium, stable, and strong wall.

2. The Budget Wood Alternative: Luan/Underlayment

Quality	Assessment	Notes
Stability	Fair/Good	Much less stable; warps easily when stored.
Moisture	Good	Some products (like Revolution Ply) have an integrated moisture barrier.
Screw Retention	Moderate	Lighter weight, not as strong as Baltic Birch.
Cost	Low	Great for saving money.
Finish	Varies	Best used when wrapped in fabric.
Use	Cost-saving, ceilings, and surfaces that don't hold heavy loads.	Excellent for ceilings as its flexibility helps it contour to the roof.

3. The Industrial Choice: Max Metal / Alu Panel

Quality	Assessment	Notes
Stability	Excellent	Composite material (aluminum skin, polyethylene core)—never warps.
Moisture	Excellent	Completely waterproof.
Weight	Moderate	Heavy, but great for raw, finished look.
Finish	Industrial	Pre-finished in various colors (e.g., matte white, brushed silver).
Use	Work vans, doors, backsplashes.	Not recommended if you plan to wrap it in fabric—the cost doesn't justify it, and it increases echo/noise.

4. The Acoustic Option: Felt (AVC Felt 1.0 Kit) NEW!

Quality	Assessment	Notes
Stability	Excellent	Made from $\text{100\%}$ acoustic felt, won't warp or buckle.
Weight	Feather-light	Weighs about a quarter of a wooden wall kit; great for payload.
Sound	Superior	Excellent sound-dampening and acoustic absorption properties.
Finishing	None Required	Comes pre-finished and ready to install.
Sustainability	Excellent	Often made with post-consumer recycled materials and no VOC-heavy glues.
Use	DIY focus, reducing noise, and saving weight.	The easiest and quietest option. Great for a sleek, clean finish that cuts down on road noise.

5. Plastic/Coroplast/Hexagon

Quality	Assessment	Notes
Stability	Poor	Warps and expands significantly with heat, causing panels to "pillow" out.
Screw Retention	Very Poor	Not durable for attaching accessories.
Cost	Very Low	Inexpensive option, but often requires replacement due to warping.
Use	Extremely budget-conscious builds where aesthetics are not a priority.

Materials to AVOID

Just as important as knowing what to use is knowing what not to use.

Crummy Big Box Store Plywood: Cheap $\frac{1}{2}\text{-inch}$ or $\frac{1}{4}\text{-inch}$ plywood is often full of holes and voids. It has poor screw retention and is a waste of time to cut and prep.
$\frac{3}{4}\text{-inch}$ Cabinet Ply: This is far too heavy for a wall kit. $\frac{1}{4}\text{-inch}$ or $\frac{1}{2}\text{-inch}$ Baltic Birch offers similar strength at a fraction of the weight.
Straight Metal Panels: Materials like $\text{.040}$ or $\text{.080}$ aluminum are expensive and offer no real advantage over Max Metal. They'll also be very loud and prone to echoing.

Final Thoughts

If you want the strongest, most premium wall, stick with Baltic Birch. If you want the quietest, lightest, and easiest installation with a modern finish, our Felt Kit is the way to go. If you are extremely budget-conscious and plan to wrap everything yourself, Luan is a functional alternative. That's all! Thanks for reading!