Cabinetry Materials for a Van Conversion
Tips on lightweight materials and construction for a mini-motorhome buildout. December 28, 2005
Do you have any suggestions for the overall conversion of this B-Class Sprinter Van? What lightweight, rigid material should I use for box construction, doors, etc.? What lightweight countertop choice for damage resistant surfaces? The weight factor of any or all materials used is of significant importance.
Kydex is a good product for your application.
One product is Ultralight from Moreland Company. Although it's not on their website, they also have a product called "BalsaPly." And as the name implies, it has a balsa wood core.
Much of the cabinetry in motor homes is 1/4" or even 1/8" panels overlaying a frame of 1/2" or 3/4" pine, along the lines of a hollow core door. Thinner products are used throughout as well. Countertops are occasionally hollow, but typically 3/4". I think the "thump" factor is an issue for manufacturers. People perceive the hollow sound as cheap, (and they might be right!). Might want to stroll around a motor home lot to get ideas.