Campervan Conversion Ceiling

Unless you want to stare up at insulation and roof beams, you are going to want to install some type of ceiling in your van conversion. In this How-To Guide, we will detail step by step how we installed a simple ceiling in our camper van conversion. We hope you can take away some tips and ideas to help you with your Campervan Conversion Ceiling.

Campervan Conversion Ceiling Installation How-To Guide

Now some of you van builders may be lucky enough to have a factory headliner already installed. But, if you are starting your DIY Campervan with a bare roof, you are going to have to tackle the project of installing a ceiling in your campervan conversion. Keep reading to see how we did it.

Key Requirements For Our Campervan Conversion Ceiling:

• Removable – In case we need to access the ceiling void to run new wiring for possible future upgrades. Also, we will be staining the ceiling to start but plan on wrapping the ceiling pieces in fabric at a later date (maybe).
• Lightweight – To help limit unnecessary weight, as well as, keeping the total van weight down. We want to use the lightest possible material.
• Low Cost – Material costs quickly pile up! We want to keep the ceiling costs as low as possible.
• Easy To Work With – ideally, most of the cutting will be done on the panel saw by the wood supplier.
• No Loss Of Standing Room – Standing at 6’3”, my head is already close to touching the roof. We want to keep the loss of headroom to a minimum.

Campervan Ceiling Material – 5’x5’x⅛” Baltic Birch Plywood

In order to meet the key requirements for our campervan conversion ceiling, we have decided to use ⅛” Baltic Birch Plywood as the material. The beauty of Baltic Birch panels is it is super strong, lightweight and it comes in 5×5 foot sheets. This is perfect for use in our Ram Promaster as each of the ceiling panel areas is approximately 5×2-½ feet. This means two sheets cover the full area of the ceiling with very minimal waste.

Now Let’s Get To The Fun Part

Installing The Ceiling In Our Campervan Conversion – How We Did It

Step-1 Collect all Tools and Materials

Home Depot doesn’t carry Baltic Birch plywood, but your local specialty wood supplier should be able to get it. We got ours from Windsor Plywood. Also, your local custom metal shop should be able to cut the galvanized sheet metal to size for you. We got our sheet metal at Metal Supermarket.

Tools and Materials List

• 2 sheets of 5x5x1/8” Baltic Birch Plywood ripped at 26-½”, 27-½”, 28-¼” and 30”.
• 3 Pieces 55”x4-½” 16gauge galvanized sheet metal
• ⅝” Aluminum Channel
• Sikabond polyurethane adhesive
• Light Solvent
• Scotch Pad
• ¼-20 RivNut Inserts
• RivNut Tool
• ¼-20×1/2” machine screws
• Jigsaw With Wood Blade
• P60 Grit Sandpaper

Step-2 Prepare and Install Sheet Metal Hangers

We wanted to avoid drilling holes into the van, we designed and fabricated a simple sheet metal plate with four RivNut Inserts on each side. We used a scotch pad to de-gloss the bonding surfaces. Then, we then glued them up to the roof support cross members using Sikabond.

Step-3 Install Aluminum Channel End Supports

For an easy and clean way to support the front and rear ceiling edges, we simply glued up some ⅝” aluminum channel using Sikabond. De-glossing the bonding surfaces before install. We then, used spring loaded curtain rods to hold it in place while the adhesive set.

Step-4 Notch Out The Campervan Ceiling Panel Material

We used cardboard to get a rough template for our cut mark, then finished the cut lines using a square to make everything is nice and straight. Next, we notched out our campervan ceiling material with a jigsaw and wood blade.

Step-5 Cut Out And Reinforce The Hole For The Roof Vent Fan

After cutting out the hole for the Roof Vent Fan, we reinforced the hole with some ¼”x1” wood trim. The trim will also give the Interior Garnish Ring screws something to bite into.

Step-6 Locate And Drill Mounting Holes

To Locate the mounting holes, put a screw in each hole, then, we held the panel up in place and gently tapped the screw area with a rubber mallet. This transferred the screw location onto the wood panel. Next, we drilled out the holes and lightly sanded all rough edges.

Step-7 Installing The New Campervan Conversion Ceiling Panels

This part was the most satisfying, hold the panels up and install the mounting screws.

Job Well Done!

We will finish the panel surfaces once the rest of the van paneling is completed.

Before you put up your DIY Camper Van Ceiling, you should think about Soundproofing your van

• How To Install Sound Deadener In A Van
• Installing Sound Absorbing Heat Shield In our Promaster
• Everything You Need To Know About Soundproofing A Van

Need some simple tricks to for installing a floor in your Campervan Conversion?

• Tips For Installing Campervan Flooring
• Conversion Van Carpet Instation Made Easy!
• The Easiest Way To Add A Floor Covering In Your Conversion Van

Thanks for reading, and remember to always take the road less traveled!

Weekender Van Life – Van Life Blog – weekendervanlife.com