I toiled for weeks trying to figure out what the heck to do with the space above the bulkhead in my van. After considering all my options, I decided that some van bulkhead storage would be the most effective use of space. However, even after making this decision, things didn't get easier - it's an awkward space in which to build. Eventually, I built some beautiful cupboards. In this illustrated guide I will show you how to build van bulkhead storage.
Shane, the founder of The Van Conversion, is a campervan professional dedicated to helping people transform ordinary vans into homes on wheels. He authored Roaming Home and teaches The Van Conversion Course, guiding many people through their van builds. Shane also writes The Van Conversion Newsletter, where he shares practical tips and insights. After completing two van builds and living on the road full-time since 2020, he is passionate about sharing his expertise with others.
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Design the Bulkhead Storage First
Before hopping into carpentry and campervan furniture making, it is essential that you mock it up on paper or with CAD software first. Here is a full guide on campervan design that will help you get started.
I highly recommend Vanspace3D for designing your campervan interior - it's an awesome drag n' drop CAD tool specifically for van conversions.
How to Build Van Bulkhead Storage
In a van, the space above the bulkhead is an awkwardly-shaped cavity above where the driver sits. It's a large area and the best use for it is certainly van bulkhead storage.
Step 1: Insulate the Bulkhead Space
Don't forget to insulate the van bulkhead space before starting work! You can learn all about campervan insulation here. I used spray adhesive to line my bulkhead space with insulating mineral wool. If I were to do it again, I would have glued some wooden furring beams to the roof of the bulkhead using an adhesive glue. I would have then insulated between the furring. This would have allowed me to ply-line the roof of the bulkhead space.
Instead, I installed a Reflectix vapour barrier on top of the insulation and stuck autocarpet directly on top.
Step 2: Install the Base
Next, cut some lengths of 1x1 timber and glue it to the base of the van bulkhead storage using Sikaflex. This will form the base furring. Let this dry for a few hours with a weight pressed on top.
Add some insulation between the furrings and then cover the insulation and furrings with a layer of Reflectix which will act as a vapour barrier.
Finally, cut a piece of a plywood to fit the shape of the base of the van bulkhead storage. Screw it down into the wooden furring.
Step 3: Install Side, Centre, and Base Support Furrings
The next step is to install side and base support. I screwed the side support on each side directly into the metal of the van with self-drilling screws. The base support was screwed into the plywood base.
Then, install a centre support furring, which will be important for the door. This is screwed in using pocket hole screws (Kreg screws). The bottom screws into the base support, and the top screws into a roof furring which was installed when we cladded the roof.
At this point, you can also optionally install separators to divide your bulkhead storage into smaller compartments.
Step 4: Install a Door
I built two swinging doors using lengths of tongue and groove cladding. First, slot the lengths of tongue and groove together. Then screw two horizontal lengths of tongue and groove into the back to hold them together. You will need to use very small screws here to avoid breaking through the thin wood.
Attach each door to the side furring using two strap hinges. Add a latch to the middle, and install a door knob on each door.
The final step of your van bulkhead storage is to install some stripwood around the edges of each door. This is purely decorative, but it frames the door panels and is a lovely final touch. I painted my doors white to make them pop and add some protection.
Conclusion
That's all there is to building campervan bulkhead storage. It's a comparatively simple build but essential for getting the most out of your space. With this done, you might like to move on to designing and building a full-sized cupboard or a kitchen unit.
Before you get started, make sure you check out the excellent VanSpace3D for experimenting with your furniture layout and design.
If you're still confused, check out our carpentry masterclass for an in-depth, step-by-step course on the whole process.
Don't forget to subscribe to The Van Conversion Newsletter for everything you need to get started with your own van conversion. We'll send you a free wiring diagram when you join.
If you're looking for some guidance with your van conversion, you might be interested in our book, Roaming Home, or in our online course, The Van Conversion Mastery Course. You'll learn directly from our founder Shane how to convert a van into your dream home - no prior experience needed.
Until next time.