Plywood has gained popularity in campervan conversions and is a favourite choice among both professional builders and DIY enthusiasts alike, and for good reason. We recently spoke with Kieran, the Director of Kitle, a seasoned expert in quality van conversion kits, to learn why plywood is such a staple material in this craft, and how to use it effectively.
Ply online: What are the key factors to consider when choosing plywood materials for a van conversion in Australia?
Kieran: When it comes to choosing plywood for our van conversion kits, we're looking for a product that is durable, aesthetically pleasing and easy to work with. After trying a number of different products, we always come back to birch plywood. Its many plies and smooth grain give a great cut edge straight off our CNC machine requiring minimal clean up.
We've also found it to be super durable even in smaller thicknesses. Generally, we use a film-faced birch ply either with a colour or a clear film, this further protects the timber from wear and tear and the elements of outdoor living. The exposed edge or face grain of birch plywood always looks stunning too!
Ply online: What are the most common design mistakes you see in DIY van builds, and how do you avoid them?
Kieran: The biggest challenge with building a campervan is maintaining flexibility, especially if you're building a weekender and not a full-time touring van. That's why we make our conversion kits modular and transferable between vehicles.
You can instantly go from an empty van to a functioning camper with a bed, kitchen, fridge, water system and storage just by bolting in the kit.
You can also easily remove the camping kit to utilise all the space in your van for moving large items too. And, if you ever need to upgrade your van in the future your camping kit can come with you!
Ply online: We know that for van builders, weight is one of the major concerns. A lighter build ensures better fuel efficiency and reduces the overall strain on the vehicle. How do you ensure the build adheres to Australian road safety regulations, especially regarding weight limits and vehicle compliance?
Knowing the gross vehicle mass (GVM) and carrying capacity of your van, and staying under that limit, is a crucial step in van conversion. Equally, making sure any cabinetry installed is firmly secured is also a must.
Even our larger fully featured conversion kits only weigh approximately 120kg and are firmly secured to load rated mounting points in the cargo area of the van.
Ply online: What are your thoughts on integrating sustainable and eco-friendly solutions into van builds, particularly in terms of materials?
Kieran: We only work with reputable suppliers for our plywood that can provide FSC certified products and data sheets from the manufacturer.
We will always avoid cheap, low-quality plywood where the timber species, timber origin and glue type used can't be verified. Investing in a high-quality material also leads to a high-quality product that will last many years unlike cheaper materials that often break and are disposed of quickly.
We never compromise on quality whether that's in the structural elements such as plywood/aluminium or the accessories that are included in our kits such as fridges/mattresses.
We've spent years of trial and error finding the ideal suppliers to partner with. When you find the right ones, stick with them!
If you'd like to find more about the many applications of plywood, feel free to reach out to us.