Aluminum extrusion can make a van's cabinet frames modular and accessible. Choosing profiles, joints and vehicle attachments requires more than a preference for one brand or a tidy layout. Start with the loaded furniture and its attachment requirements, then compare materials and costs.
1. Compare Profiles And Complete Project Costs
Compare exact part drawings, dimensions and compatible hardware. 80/20 is a brand; “2020” can describe a metric size or appear in a different manufacturer's part number. The 80/20 And 2020 Comparison explains that distinction.
Get quotes for the same intended assembly, including connectors, machining, shipping and tools. Keep price comparisons tied to specific parts and dated quotes.
Compare Extrusion And Wood-Based Cabinet Construction
Compare two ways of building the same cabinet, rather than a length of extrusion against a sheet of plywood. Keep the intended use, outside envelope, storage opening and contents the same. Then identify the parts, work and unresolved requirements for each option.
| Option | Identify In The Proposed Assembly |
|---|---|
| Extrusion Frame With Panels | Exact profile lengths and series; compatible connectors and fasteners; panel mounts; panels and edge treatment; door or drawer hardware; machining and assembly access. |
| Wood-Based Cabinet | Actual timber species and grade or panel product and thickness; the proposed joints and fasteners; any separate framing; finish and edge treatment; door or drawer hardware; assembly and inspection access. |
“Aluminum” and “wood” are starting labels, not complete specifications. A plywood cabinet and a timber frame with panel infill also need different part lists. Use the cabinet-panel comparison when identifying the panel itself.
Compare Fabrication And Later Changes
Compare connection preparation before budgeting tools. 80/20 specifies access-hole machining for its 13192 45 Series bolt connector, while its 9290 Quick Frame connector requires no machining service. These belong to different systems.
For the wood-based option, identify the cutting, joint preparation, fastening and finishing work required by the proposed design. If using structural plywood data, check the exact product and orientation: APA explains that panel properties depend on grade, thickness and loading direction.
- Weight: Compare the complete empty assemblies using product-specific data or measured parts, with units recorded. Include panels, connectors, hardware and finish. Record the intended stored load separately; neither material name supplies a finished weight.
- Cost And Work: Use dated quotes for the full part lists, machining, delivery, consumables and any tools still needed. Note which tasks you will do and which require outside fabrication. Keep time estimates separate from observed build time.
- Future Access: Identify which panel or member would have to come off to reach equipment, how its connection would be released, and whether the opening remains useful after the finish is installed.
Record the selected approach, supporting drawings and unresolved questions in the project decision record. Model the actual member and panel thicknesses in the layout and finish workflow. Keep the choice provisional until the loaded cabinet's joints and vehicle attachment requirements are resolved in the checks below.
2. Verify Vehicle Attachment Points
Identify the vehicle's model year and configuration, then check its body-builder documentation before selecting attachment points. A rivet nut also needs the correct panel, hole, grip range and installation requirements.
Map the path from the loaded cabinet through each joint and attachment into the vehicle structure. Keep access for installation and inspection.
3. Consider Loads In More Than One Direction
A supported beam can carry a downward load, but gravity does not retain furniture during braking, cornering, vibration or a collision. Connections must address the assembly's required loads and restraint, not just how it stands while parked. Aluminum material alone does not make a cabinet crash-safe.
The two original layout drawings below compare which member continues through a joint. They help explain the cabinet-and-stove layout choice.
For a selected profile, the 80/20 Deflection Calculator uses its part number, span, load and support configuration.
4. Separate Appearance From Structural Requirements
I prefer visible black extrusion in this build. That is an aesthetic choice, not evidence of greater strength. Plan how panels attach and how you will reach fasteners before covering the frame. Do not add framing solely to make it visible and assume the result is stronger.
The DIY Cabinet Guide covers the surrounding project, while Quick-Release Options helps compare access and removable fittings.
5. Plan Cuts And Service Access
Model the actual profiles and fittings, check measurements in the van, and create a cut list before ordering. Fewer cuts may reduce work, but the joint design and access requirements determine where members end. Leave room to assemble, tighten and inspect the chosen connectors.
Use the SketchUp Layout Guide to test furniture footprints and openings. A model helps plan the layout.
6. Check Drilling Restrictions Before Altering The Van
Do not treat drilling through the floor as a universal cabinet-mounting method. Ford's 2025 General Body Builders Layout Book (PDF), under “Second Unit Body Structures And Mounting,” directs upfitters to the vehicle-specific BEMM or BBLB before drilling a unibody vehicle. It also identifies precautionary and no-drill zones and the need to protect components below the floor.
Find model-year documents through Ford Pro Upfitter Publications. Keep the attachment design, corrosion protection and sealing details together.
Do not remove or repurpose cargo tie-down fittings without checking their intended use and the proposed installation's requirements. Keep the selected drawings, hardware specifications and mounting instructions with the build records so the completed assembly can be inspected and maintained.