Building out a camper van isn't just about throwing some wood together. It is a technical puzzle where every single inch matters. When you're sleeping sideways inside a rig, two extra inches make all the difference.The Millimeter GameI spent all morning in the garage dialing in the main cabinet drawers. I built out the primary wooden slide-outs, mounted the side tracks, and test-fitted the white front face panels. Everything glides smoothly now. But the real challenge was waiting inside the van itself.I needed maximum headroom and length for the sleeping setup without sacrificing structural support. The solution? Sunken headboards.AdvertisementAdvertisementBy pushing the plywood headboard panels back into the wall cavities, I managed to carve out almost two additional inches on each side of the van. When you're over six feet tall, those extra four inches total mean the difference between a good night's sleep and hitting your head against the wall.Progress On The BuildPrecision takes time. Rushing the framing means dealing with persistent rattles down the road, and I need this build to hold up on rough terrain.Cabinetry: Custom plywood drawer boxes with soft-close slidesRear Doors: Fully finished tongue-and-groove wooden panelingSleeping Area: Sunken plywood headboards recessed for extra widthNext Steps: Installing main wall paneling and securing the seating benchThe progress is real. With the back door paneling finished and the headboards mounted flush, the rig is finally taking shape. Tomorrow, we take on the rest of the main wall panels.
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