The next bigger decision that you'll make is around the framing for your van interior. The general consensus if you read long enough or watch enough videos seems to be that there's no substitute for 80/20 aluminum construction. Having done one camper with 80/20 and one without, I think the reality is more nuanced than that - and there's a cost angle that almost nobody talks about.
For those unfamiliar, 80/20 (also called T-slot aluminum or aluminum extrusion) is a modular framing system made of aluminum profiles with slots running along their length. You can bolt pieces together at any angle, and the slots accept special T-nuts that let you attach panels, shelves, or hardware anywhere along the length.
It's commonly used in industrial applications, automation, and increasingly in high-end camper van builds. Think of it as adult Legos made of aluminum.
There are legitimate reasons people love aluminum extrusion. If you have unlimited time and budget, it's objectively superior in many ways:
Cost is usually listed as the #1 argument against aluminum extrusion, and if you're buying from the name-brand 80/20 company or similar suppliers, it absolutely is:
But here's what most build guides won't tell you: generic 2020 T-slot aluminum extrusion is available for a fraction of that price. Vevor sells a 10-pack of 78" (2000mm) 2020 extrusion for around $120 - that works out to roughly $1.85 per linear foot. That's comparable to wood framing costs and completely changes the cost equation.
Compare to wood:
With generic extrusion, the raw material cost gap is much smaller than people think. The real cost difference comes from the hardware (brackets, T-nuts, bolts) and especially the time investment - which brings us to the next point.
This is where my experience really comes into play. Cutting and assembling the frame is straightforward - measure, cut, bolt. But then comes everything else:
Overall: an 80/20 build takes 2-3x longer than wood for the same result. That cabinet that would take a Saturday with wood? Plan on a full weekend with 80/20, plus ordering parts you didn't realize you needed.
Use 80/20 strategically where it provides the most benefit, and use wood everywhere else.
This hybrid approach gets you maybe 60-70% of the weight savings for 20-30% of the cost and time. That's a good trade-off for most people.
Let's look at a real example - a kitchen cabinet 24" wide, 18" tall, 16" deep:
Notice that for cabinets specifically, the hybrid approach barely saves weight over all-wood (24 vs 25 lbs) — the plywood panels dominate the weight either way. The real weight savings from 80/20 come from pairing it with thin composite panels (which add significant cost), or from applications like bed frames and heavy-mount points where you're replacing larger wood members and the weight delta is much bigger. Across a full van build, these differences multiply - but so do the cost and time differences.
For most first-time builders:
Use wood for the majority of your build. It's cheaper, faster, more forgiving, and easier to modify. Your van will be plenty strong and functional. People who go all-in on 80/20 for their first build often get bogged down and spend months or years — sometimes never finishing.
Consider aluminum extrusion for:
Bed frame if you want to save weight there, or specific mounting points for heavy items. Use generic 2020 extrusion from Vevor instead of brand-name 80/20 - it's the same aluminum profile at a fraction of the price.
Avoid:
Trying to build everything in 80/20 unless you have extensive experience, a large budget, and plenty of time.
Remember: the goal is to build a van you'll enjoy using, not to win a "who used the most aluminum extrusion" contest. Get out there and start camping sooner rather than spending months perfecting an elaborate 80/20 design. You can always rebuild or upgrade later if you decide the weight savings matter to you.