Maximize Your Space: Installing a Vancillary Headliner Shelf in Your Van

Hey everybody, Matt here for AVC and welcome back to the shop! On today's post, we're tackling a popular van upgrade that adds valuable storage and a touch of personalization: installing an over-cab headliner shelf using Vancillary brackets.

If you're not familiar with Vancillary, they specialize in clever, simple solutions for van conversions. Their over-cab shelf bracket is a particular favorite of ours. Instead of shipping a bulky, expensive shelf, they provide just the essential components:

• The Brackets: Designed to insert above the cab and connect to your custom-made shelf.

• A Full-Size Paper Pattern: This makes it incredibly easy for you to cut your own shelf at home, giving you full control over the material and finish.

• All Required Hardware: To ensure a successful installation.

While the standard install is straightforward, we decided to do something a little more custom for my personal van – a unique homage to my father's old camper van.

Our Custom Headliner Shelf Design

In the past, we've typically built these shelves from 1/2-inch Baltic birch plywood, then wrapped them in headliner material or a light gray fabric to match the van's interior. This time, I wanted to incorporate a personal touch: a cork bottom. My dad's old van had a cork headliner where he'd pin race tickets, concert stubs, and mementos from our travels. I thought it would be a cool way to keep family keepsakes and memories pinned up here in my own van.

Our custom shelf features:

• A 1/2-inch front piece for rigidity across the span.

• A 1/4-inch Baltic birch shelf above that.

• A 1/2-inch layer of solid cork on the bottom, offset with a 1/2-inch gap to sit flush with the front lip.

• A 1/4-inch padded lip at the front, offering a soft buffer if you accidentally bump your head!

• The top of the shelf is fabric-covered to blend seamlessly with the van's headliner, ensuring a quiet, integrated look.

This layered approach provides a super sturdy shelf that's also a cool, custom feature. Let's get to work on the install!

Installation: Step-by-Step Guide

Installing the Vancillary over-cab shelf is quite simple, even with our custom modifications.

Step 1: Install the Vancillary Brackets

1. Locate the existing handle mounts above the cab. The Vancillary bracket has a slight "rise" to it – this rise should face upwards.

2. The bracket will be sandwiched between the headliner and the handle. This slight rise ensures the shelf sits above your sunglass holder area.

3. Remove the two bolts holding the handle in place. Be aware: Ford used two different sizes here! The back bolt is an 8mm, and the front bolt is a 7mm. Don't ask us why, it's just how they roll!

4. Position the Vancillary bracket, then reinstall the handle and its bolts. For this first step, just get them in place loosely; you don't need to super tight them yet.

5. Repeat for both the driver and passenger sides.

Step 2: Test Fit the Shelf & Mark Holes

1. With both brackets loosely in place, carefully test fit your custom shelf. It might be a little tight going past some of the factory "go-code blobs," but once it's in, it should fit perfectly.

2. Once the shelf is in position, use a Sharpie to mark the three mounting holes from the brackets onto the underside of your shelf.

3. Additionally, if your van has the central hole located behind the sunglass boxes (visible if you remove them), mark that as well. This extra mounting point helps lock everything together.

4. Remove the shelf.

Step 3: Prepare the Shelf for Hardware

1. At your workbench, drill out the marked holes on your shelf. While Vancillary provides hardware for a standard 1/2-inch shelf, our custom 3/4-inch shelf required slightly longer 1/4-20 bolts. (Fortunately, the Vancillary brackets are already sized for 1/4-20, so no need to drill them out!)

2. For a super low-profile finish on our custom cork shelf, we opted for sidewalk or elevator bolts for the center mounting point, as their flat heads won't stick up.

Step 4: Final Shelf Installation

1. Carefully lift your shelf back into position in the van.

2. Insert all your mounting bolts through the shelf and into the Vancillary brackets. Get all the bolts started by hand before tightening.

3. Using a socket wrench on the bottom and an open-end box wrench on top (especially for that back bolt that's tight to the headliner), tighten all bolts securely. Ensure the bracket is properly seated against the headliner.

Why Add a Headliner Shelf?

Once installed, a headliner shelf becomes an incredibly useful addition to your van:

• Shade Storage: It's the perfect spot to neatly store all your van essential window shades for the front of the van, keeping them organized and easily accessible.

• Longer Item Storage: Ideal for stashing longer items like an awning arm, fishing rods, or even fun items like a BB gun or blow-dart gun!

• Quick Access Essentials: Keep tissues, snacks, or other frequently used items within easy reach from the front seats.

• Personalized Keepsake Display: For our custom cork shelf, it's a wonderful place to pin up family photos, souvenir pins from road trips (like our PCH and Oregon coast pin!), and other mementos, making the van truly feel like home on the road.

This headliner shelf not only adds practical storage but also offers a unique opportunity for personalization, reflecting your adventures and memories.

This is just one episode in our build series for our 2025 show vehicle. If you want to follow along with every step, hit that subscribe button! And if you found this video helpful, please hit the like button so others can find it.

Looking to get a van professionally built by AVC? There's a link in the description below – our team will help you get your project started.

Now, I want to hear from you! I built this shelf as an homage to my father and to keep family keepsakes. What are your ideas for a custom headliner shelf you'd put in your van? Let me know in the comments below – I'm curious to see your thoughts!