How to Insulate a Van Conversion Step by Step
Insulation is not about R-value bragging—it is about condensation control and noise. Metal vans sweat when warm moist air hits cold walls. Your insulation system must address vapor movement, not just heat loss.
Typical layer stack
- Rust treatment and primer on bare metal
- Butyl or foam deadener on large panels (optional, helps road noise)
- Insulation in cavities—wool, polyiso boards, or Thinsulate-style products
- Vapor-permeable or controlled vapor layer depending on climate strategy
- Plywood or composite subsurfaces for walls and ceiling
Common mistakes
- Stuffing fiberglass against bare metal with no air gap management
- Sealing every hole so tight that moisture has nowhere to go
- Skipping floor insulation under plywood subfloor
Research your climate. Cold-wet regions need different strategies than dry desert travel.
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