Build Question about Materials

[Jack]

Whichever vehicle I end up with, I want to be sure to maximize my gas mileage.  Part of that is keeping the weight of the build down as much as possible.  

I love wood.  I'm a log cabin and flannel kind of guy.  However, I live in a 1970's apartment building in a big city which means everything looks dated and like your usual non-remodeled apartment.  As much as I want the wood look, is there a lighter material I can use?  I also want to keep costs down and be sure whatever materials I use will help guard against condensation and mold. 

I thought about finding faux log cabin paneling (if it looks good) but, I don't know.  I'm not a builder and I would imagine that kind of thing would be pricey anyway.  I'd really appreciate suggestions on build materials.

 

[highdesertranger]

for the ceiling and walls 1/8 inch plywood is great. it's light weight, cheap and easy to work with. highdesertranger

 

[Jack]

That sounds great. I imagine you'd have to make sure everything is very secure while driving because wouldn't 1/8" plywood puncture easily?

 

[Van-Tramp]

Yep, the 1/8 inch ply is your best bet as long as you want rigid walls/ceilings.

You could think outside the box and go with stretched fabric coverings for the walls/ceilings (insulation behind it). Could make for an interesting look and feel inside a van and about as light weight as you can go. All you would need is some scissors and glue to build it.

 

[Jack]

I thought about fabric (like denim) covered walls but decided against it for two reasons:  1) if it tears or punctures, you have to redo the whole wall if you don't want patches.  And 2) fabric absorbs odors.  Other than that, some denim and a red and black plaid flannel highlights would suit me fine.

 

[bullfrog]

Insulation foam covered with glued on brown paper or cloth is strong and easy to repair. You could use strips of thin wood to hold it to the van ribs. Glue screen wire under the paper or cloth and you can actually make cabinets strong enough to hold food items.

 

[Van-Tramp]

Ah yea that would work. You could even put a coat of fiberglass resin to really bond things together. Add in a single layer of fiber glass fabric and you are in great shape. Easily paint-able as well. Repair with more fiberglass and even bondo and sandpaper. Probably cost prohibitive and I'm not so sure it would save too much weight in the end.

I once saw a 6 X 12 trailer for sale and it was made almost exclusively of the rigid board foam glued together. There was a small wooden frame to hold the basic structure, but the foam board was 90% of the materials. He then covered it in urethane paint or something to protect it. Lighter than wood by far. The problem I saw was using it to travel anywhere at 60 MPH and a single stone or stick would puncture it and cause the entire thing to explode on the highway.

Going back to the fabric - the patch-work repairs would look pretty cool over time I must say. It sure would be unique. Just have to mount any shelving to the floor firmly so the walls do not need to be used. I suppose a single horizontal board screwed to the ribs would work as mounting points as well... why not.

 

[QinReno]

Hit the road, Jack.
https://vanlivingforum.com/showthread.php?tid=32941

 

[Canine]

For my ceiling I used sheets of 1/2 inch, fiberglass-faced, 1000 psi, polyiso insulation. Then I painted it with a quality, latex paint. It turned out great! Very durable, lightweight, and it's also high quality insulation. It won't hold a screw, so if you want to hang anything from the ceiling, then your out of luck there.

I had looked into various plastic sheets that replace plywood and they looked perfect. But they are $$$$. You can find them at marinas.

There are also PVC studs if that interests you. They aren't solid plastic; they are made like the metal studs.