Planning Your Van Layout: A Deep Dive

Planning Your Van Layout: A Deep Dive

We’ve built over 140 vans now at Roost Vans. We’re primarily a van interior product company: an ecosystem of products that all mount to our Smooth Rail Mounting System, installed into Sprinter, Transit, and soon RAM ProMaster class B camper vans. We don’t chase heavily customized one-off work. Instead, we’ve built a standard product line with a lot of modularity, which lets us build high-quality vans quickly and lay them out in a lot of different ways at a tremendous value.

Start With Priorities, Not Products

Layout planning starts with assessing what you actually want out of the van, roughly in this order of impact on floor space:

  1. Seating — has the single biggest impact on layout
  2. Sleeping — side to side, front to back, dinette or garage, next biggest impact
  3. Kitchen — How functional, or how simple
  4. Storage — What cabinets to use vs open space to keep
  5. Power — How long do you want to be off grid vs how much do you want to spend

We use a detailed client questionnaire to work through this, and almost every one comes back wanting everything. That’s completely normal, but a class B camper van doesn’t defy the laws of physics. Something has to give, and figuring out what matters most to you is most of the work.

One detail that surprises people: within the Sprinter and Transit lineup, body length doesn’t scale the way you’d expect. The 144 Sprinter and 170 Sprinter sit at opposite extremes, while the Transit’s regular 148 wheelbase and extended 148 body land in between. A layout that works beautifully in a regular 148 (technically a 148L) won’t necessarily translate to a 144, because you can simply run out of room.

Our Design Tools

A few tools we lean on for every layout:

  • Mood boards — before committing to materials, we map out how much bamboo, Hexply flooring, and other colorways will actually show. It’s easy for a van interior to get visually busy fast, and a mood board catches that before it happens.
  • Inset panels — instead of flare spaces, inset panels around the windows gain you 4 to 6 inches of usable width for side-to-side sleeping, plus a cleaner look.
  • Three functional zones — seating, kitchen, and sleeping. These can overlap, and how much you let them overlap is one of the biggest layout decisions you’ll make.
Collage of material samples: gray fabric, light and medium wood, gray metal, a black rail, and reddish-brown tiles across a swatch board.

Zone by Zone

Seating: A second-row bench seat gives us a mounting point for a much larger Lagun articulating table, since we can anchor to the seat’s frame instead of the wall.

Kitchen: Our Flip-Up Kit bed system at bike and counter clearance can store a bed panel over the kitchen, extending your countertop by up to 24 inches when folded up. Exposed only when you need it. A standard passenger-side kitchen cabinet adds exterior fridge access and a flip-down outdoor table, which pairs well with an awning.

Sleeping: Three main approaches: a dinette, an elevated Flip-Up bed platform, or our hanging Strap-Up Bed System, which raises to the ceiling or lowers to the wheel wells and can level itself out even when the van’s parked at an angle.

Storage: We’ve found sliding pull-out trays look great on paper but tend to bind once a van is actually loaded. Our Flip-Up Bed gives comparable garage access without that problem.

Power: We’re strong proponents of portable power stations, Goal Zero and EcoFlow especially, because for the price you get an inverter, engine charger, up to a roughly 400 amp-hour battery bank, and a solar charge controller in one simple unit. Versus building an equivalent custom system component by component at more cost and more space.

What Real Builds Look Like

We walked through around 15 builds across four categories: short vans with extra seating, short vans with just the factory two seats, and the same two categories in long-body vans. A few patterns stood out:

  • Short bench-seated (family) vans (144 Sprinter, 148 Transit) can fit a dinette, a second-row bench with an articulating table, and either the Strap-Up or Flip-Up Kit bed, sleeping up to four. A small Kitchen size depends heavily on wheel well placement, Transit’s wheel well sits further back, so it can often fit a full two-module kitchen where a Sprinter fits one and a half. There’s still room, but not much so it needs to be planned carefully.
  • Long bench-seated (family) vans open up enough room for a full dinette, a two-module kitchen on the driver side, and a walk-through compact cabinet on the other, without sacrificing much of anything.
  • Short and long couple vans (no extra seating) get the most flexible layouts. With more floor space freed up, we can add compact passenger-side kitchen cabinets, bigger dinettes, or even dual water tank setups for owners who want to rinse off dogs or gear after every trip.

Across nearly every build, swivel seats, articulating tables, and inset paneling did the most work to make a small space feel bigger and more livable at the best value.

Not Sure What You Want? Rent First

Our best advice for anyone still deciding between a Sprinter, Transit, or ProMaster: go rent one and live in it for a few days before committing. Outfitted rental marketplaces like Outdoorsy are a great way to test different layouts and platforms firsthand.

If you want more on the Sprinter vs. Transit decision itself, we covered that in detail in an earlier webinar, now up on our YouTube channel.

Let’s Talk Layout

Every build starts with the same conversation: what do you actually need this van to do? Reach out to us at sales@roostvans.com, or browse our full DIY product lineup, knowing more is available for in shop installation, to start getting a feel for what’s possible.

What Is a Core Build? The Foundation of a Great Van Conversion

If you’ve spent any time looking into van conversions, you’ve probably heard the term “core build” thrown around. But what does it actually mean, and why does it matter?

At Roost Vans, the core build is the first step in any van building journey. I always describe it like a sheet-rocked house. The wiring is behind the walls, the windows are in, the paneling is on. There are no cabinets, no bed, no plumbing yet. It’s a built-out shell that’s been intelligently engineered to already know where those things are going to go. So when you’re ready to take that next step, the van is ready for you.

Interior of a camper van showing a bed on the left, upper wooden cabinets, and a wood counter by a large window.

What’s Actually Included

A core build covers a lot of ground. Here’s what we typically do at Roost Vans:

Smooth Rail Mounting System: All of our vans start here, and everything after the core build mounts to this flexible robust system. A bit of up front work pays dividends in quality and speed of the main build later. Don’t build a van without it. Trust us.

Windows, Vent fan and Seating. We primarily work with AM Auto glue-in style windows, and for good reason. We’ve had far better luck with longevity and no leaking compared to clamp-in styles. Pill windows are a popular option for the back half of vans, especially if you’re planning a bed system and want airflow while you sleep.

And depending on how far you want to go, we also typically install a vent fan, a heater, pull tested seating, and any add-ons that make sense for your situation before continuing onto the electrical.

Electrical. A standardized core wiring system goes in with a switch plate and power panel for power distribution that can be integrated well with a power station. The wiring is behind the walls before the paneling goes up, so everything is clean and ready to expand.

Interior of a cargo van with wooden panel walls and ceiling, back double doors, and a black rubberized floor; LED lights along the ceiling and a ceiling vent visible at top center.

Insulation and sound suppression. When vans roll off the factory floor, you can barely hold a conversation inside them while they’re moving. That changes after a core build. We use Rattle Trap on key areas to kill the drum effect of the metal, and then we layer in Thinsulate wherever we can get it. Behind the headliner, in the ceiling pockets, behind the doors. It makes a significant difference both thermally and acoustically. We don’t over-engineer it chasing diminishing returns with 100% coverage, but what we do is targeted and effective.

Paneling. We primarily use bamboo, and it’s a material we’re genuinely proud of. Finished in Osmo hard wax, it’s easy to maintain and refinish. No outgassing and lasts for years and years. Unlike laminate. Paneling is also available as unfinished baltic birch, or fabric-wrapped. The upper, mid, and lower wall paneling all integrate directly with our smooth rail mounting system, and everything is serviceable, meaning you can pull a panel without dismantling your whole build.

Flooring. We use a half-inch hex ply anti-skid flooring material, screwed into rivnuts so the floor stays serviceable if you ever need to get under it. It comes as a DIY-shippable kit, or we’ll install it in the shop.

Why It’s Built Around the Smooth Rail System

Everything in the core build is designed around our interior Smooth Rail Mounting System. It’s what makes the whole thing flexible. When you have a vehicle traveling down the highway at 75 mph, you want every component locked in securely. But you also want the ability to move things around, swap out components, or add to the build later. The rail system makes all of that possible without pulling apart the whole van.

The Phased Build Approach

One of the biggest reasons people choose Roost Vans for their core build is budget flexibility and not being 100% sure on how exactly they want their van built. Maybe you don’t know exactly how you want to use your van yet. Maybe you want to live in it for a few months before committing to a full buildout. A core build lets you drive a functional, quiet, insulated van while you figure that out.

Customers come back to us two, three, sometimes four times to add onto their build. Others get everything done at once. Either way works, and the core build is engineered to support both paths.

Some people have us do the core build in the shop, then handle everything after that themselves, using Roost products or other aftermarket components they’ve chosen. That’s a perfectly valid way to do it, and one of the unique strengths of our system.

Can You Do It Yourself?

Yes. We offer the electrical system, the mounting system, the paneling, the flooring kit, and support for insulation, vent fans, and windows as DIY products. Some customers have us come in for the pieces they don’t want to tackle, like window installation or electrical, and then handle the rest on their own. There’s a lot of flexibility there.

The Bottom Line

The core build is not the flashy part of a van conversion. It’s not the cabinetry or the countertops or the rooftop deck. But it is the reason everything else works as well as it does. A well-done core build means your van is quiet, insulated, wired, paneled, and ready for whatever comes next.

We do core builds here in our Portland, Oregon shop, and we also support builders all over the country and internationally through our product ecosystem. However you want to approach your build, it starts with Roost Vans.

What a Full Roost Vans Build Looks Like

What a Full Roost Vans Build Looks Like

Every once in a while we finish a van that’s a really good example of what a complete Roost build looks like when you stack everything together the way we intended it.

A recent 2024 AWD Transit is one of those vans.

Instead of walking you through it panel by panel, I want to zoom out a little and show you what’s actually happening underneath the pretty parts, because that’s what matters.

A full build isn’t just cabinets and a bed, it starts with the Core.

The Core Build

I say this a lot, the Core Build is like sheetrock in a house and everything underneath.

Our Core includes:

  • Mounting System
  • Electric
  • Insulation
  • Wiring 
  • Flooring
  • Upper, Mid, and Lower Paneling
  • Vent fan, windows, power station and heater

At the center of that is our: Smooth Rail Mounting System

Everything mounts to it:

If you want to add something later, you’re not drilling random holes into your van and hoping for the best. We built it this way because people need change, and we don’t like building vans that paint you into a corner.

Power

Here’s where people either overspend or underthink: Power.

In a full build like this one, we scaled it up to power and include:

  • 800 amp-hours of battery to power an autonomous Dometic RTX 2000 air conditioner
  • Engine, Shore power, and Solar charging
  • Victron monitoring
  • Espar heater

All of that runs through our: Power Panel

The idea behind the Power Panel is simple… bring all your wiring to one centralized spot so it’s clean and expandable.

It’s not magic… You still have to wire things correctly. But the heavy lifting is done and you’re not creating a spaghetti monster behind your cabinets. If you want a deeper dive into how we think about batteries, solar, and what actually drains power, I wrote a full piece on it here: Deep Thoughts: On Power in a Van 

Most people don’t need as much battery as they think they do. Unless you want to run A/C off-grid for hours. Then we need to talk.

Interior of a camper van with oak plywood overhead cabinets, a small desk, and built‑in lighting along the wall edge.

Paneling

There was a time when van paneling meant three weekends, a YouTube tutorial, and a lot of regret. We don’t do that anymore. Our paneling integrates with the Smooth Rail Mounting System so you can remove a panel later without tearing apart the van.

Upper, mid, lower: finished bamboo, unfinished bamboo, HexPly, fabric wrap… whatever direction you want to go.

In this build, we paired HexPly flooring with powder-coated trim and Minicel underneath. It’s durable, serviceable, inexpensive, finished, and best of all, it doesn’t squeak.

If you want the full rant on paneling, it’s here: Roost Vans Thoughts on Paneling

Short version: it should be clean and serviceable. Not traumatic.

Cabinetry

Once the Core is in, cabinetry becomes easy, because it’s mounting to something intentional.

In a full build like this, that can include:

Driver Side Kitchen Cabinet

Drawer Cabinet

Upper Cabinetry

We often upgrade to stranded (fossilized) bamboo countertops. They hold up, and they look good. We hide kickplate drawers in the base cabinets because there is nothing worse than wasted space in a van.

Everything ties back to the van rail system. So if something needs to change later, it can.

Sleep

Beds in vans tend to take over, ours doesn’t.

The Fu-Kit Bed System paired with our Mattress can be configured two-panel, two-and-a-half, or three-panel. You can also add our Flip-Up Kit, which gives you a sofa and garage access. Plus you gain 24” of counter top space on each side.

Keep it Simple Stupid

This build runs a 20-gallon over-the-wheel-well tank with interior fill:

  • No unnecessary holes punched in the van body.
  • Fresh water monitoring.
  • Battery monitoring.
  • Pump switch.

= Straightforward.

For toilets, we stick with the Loo Bench.

Paired with the Stansport EasyGo Loo. We like this option because there are no chemicals. no composting fans pulling power 24/7, and no diaper-genie situations.

If you want the long explanation of why we don’t overcomplicate toilets, it’s here:
Roost Vans Thoughts on Toilets in Vans <link to blog

Most people just need a place to pee at 2 a.m. Let’s not turn it into a science experiment.

Climate Control

With 800 amp-hours and proper charging, we can run:

  • Dometic RTX 2000 A/C
  • Espar heater

Heating and cooling are only complicated if the power system isn’t designed for it. When it is, it just works.

Full Build

A full Roost build isn’t about cramming every possible feature into a van.

It’s about layering systems correctly:

  • Rail system
  • Power infrastructure
  • Modular paneling
  • Intentional cabinetry
  • Flexible bed system
  • Right-sized water system
  • Simple toilet solution

Everything builds on the previous layer. That’s what you’re seeing in this Transit. It’s not flashy for the sake of being flashy. It’s built so you can use it… Fix it… Upgrade it… And not be scared of it.

We’ve embedded the full walkthrough video below so you can see how all of this actually comes together in a real van.

If you’re thinking about a phased build, a DIY install, or having us do a full conversion, this is a solid example of what’s possible.

You can explore all of our systems and products at: roostvans.com

Build it simple.
Build it serviceable.
Then go use it.

Why Choose Roost Vans for Your Van needs?

Why Choose Roost Vans for Your Van needs?

There are a lot of ways to build out a van.

Some people go fully DIY. Some hand it off completely. Many end up somewhere in between in a hybrid approach wanting help with the hard parts, but still wanting ownership over the build.

Roost fits all of these models. And that’s what makes us unique.

Start With the Hard Stuff

If you’re staring at an empty van wondering where to begin, the answer usually isn’t cabinetry or finishes, it’s infrastructure: That’s what our Core Build is for.

We bring your van into our three-bay shop in Portland, Oregon, and handle the parts that are difficult to redo later:

By the time you drive away, the van is quieter, more solid, and ready to build on further.

From there, you can take it as far as you want yourself. Some people come back for cabinetry. Others finish it on their own. Both routes work, because the foundation is already done right.

The System Everything Is Built On

At the center of every Roost build is the Smooth Rail Mounting System.

It’s not just a place to bolt things down. It’s a fully integrated structure tied into the chassis of the van. Everything mounts to it: beds, cabinets, accessories. That’s what allows the entire interior to stay secure while still being flexible.

If you’ve ever seen builds that rely on L-track or surface-mounted hardware, you already know the limitations. Challenging hardware, incremental positioning, and additional reinforcement required.

We’ve written more about that here: Smooth Rail vs. L-Track, What’s the Difference?

The short version: this system exists so your build isn’t just attached. It’s actually engineered.

Built for Flexibility, Not Permanence

Most van builds lock you into one layout, while Roost Vans does the opposite.

Because everything ties back to the mounting system, you can swap out cabinetry, reconfigure your layout, remove components entirely, and upgrade over time.

That matters more than people think. Because how you use your van in month one usually isn’t how you’ll use it in year two.

In-Shop Builds That Mirror DIY

One of the biggest differences with Roost is that we’re not building one-off custom interiors that only exist in our shop.

We’re installing the same products we sell.

  • Same cabinetry
  • Same bed systems
  • Same mounting system
  • Same paneling

So whether you have us install everything or you take parts home and do it yourself, you’re working within the same ecosystem. There’s little disconnect between a professional build and a DIY build.

This also gives us a built-in quality control loop. Every van we build in-house is a real-world test of the products going out the door to our DIY customers.

Wood cabinet doors propped on a warehouse shelf, labeled FBAM Upper Cabinet Doors (Sprinter) and Upper Cabinet Bottoms (Sprinter).

Why It Exists in the First Place

Roost didn’t start as a design trend or a product line; it started with a problem.

Our founder Dennis saw an RV accident that made one thing really clear: most interiors aren’t built with real structure in mind. When something goes wrong, everything inside becomes a liability. That stuck.

So the focus from the beginning became simple. Build van interiors that are secure, intentional, and actually tied into the vehicle. Not just for looks, not just for convenience, but for safety.

Built With Real Use in Mind

Everything we do, from materials to mounting to layout, comes back to how these vans are actually used.

We partner with local and domestic manufacturers for steel and wood components. We do a lot of our finishing and sanding in-house, using Osmo Polyx, a hard wax product that’s ecology-friendly and won’t outgas when your van heats up. Since it’s safe for baby toys, it’s safe and robust for a van interior. We engineer products that hold up to heat, movement, and time. Our products are designed to be lived in.

So, Why Choose Roost?

If you want a fully custom build with no flexibility, there are plenty of options out there.

If you want to DIY everything from scratch, that’s always on the table too.

But if you want a van that starts with a solid, engineered foundation, gives you flexibility to build over time, uses high-quality stress proven components in well over 100 van builds, and keeps safety at the center of the design; that’s what we do.

Start with the Core Build, then buy DIY our products, or build your own, or have us install them as a main build, or find some combination of all the above.

Either way, you’re building on a system that’s designed to last.

Ready to elevate your van life? Visit us at roostvans.com and see how we can help you with your adventures! 

Check out our other social channels here: https://linktr.ee/roostvans.com

Starting Your Van Journey? Start Here

Starting Your Van Journey? Start Here

So… you’ve got the idea. You want a van build, but now what?

This page is your Roost Vans roadmap: from first thought to the first time you roll it out of your driveaway. We’ve compiled a list of blogs and videos that help you with the decisions that actually matter, in the order they matter.

 

Step 1: Start Planning (Before You Buy Anything)

Start Planning Your Van Build | Roost Vans Shop Space

Before you touch a van, you need a plan. This is where most people skip ahead, and regret it later. And another thing…

Pick the Right Camper Van Chassis For You

Key takeaway:
Everything builds on your initial decisions. If those are wrong, everything downstream gets harder.

Step 2: Understand the Build Process

02 The Build Process | Roost Vans Webinar

This is the high-level overview most people never get.

What this covers:

  • Core Build vs full build
  • Order of operations
  • Where people waste time and money

 

Step 3: Layout Comes First (Not Products)

03 Planning and Layout | Roost Vans Webinar

Before beds, before cabinets—layout.

This determines:

  • How you move inside the van
  • How you store gear
  • Whether you enjoy using it

Step 4: Galley Width 

Why Galley Width Matters | Deep Thoughts With Dennis

This is one of those things people don’t think about… until it’s too late.

Too narrow = cramped walkway
Too wide = unusable kitchen

Step 5: How Builds Actually Work

Everything starts with a system, not random installs.

Watch how it comes together in real builds:

Core idea:

  • Structure first
  • Systems second
  • Finish last

Product Foundation: Smooth Rail Mounting System

Step 6: Real Build Examples

Full Custom Build: Roost Vans Build – Woods 

Simple / Budget-Friendly Build: Simple Promaster Van Build – Templin 

These show how decisions actually play out in real vans.

Step 7: Electrical 

Most people underestimate this. If I were you, I would read this blog first!

And here’s a great video on how to think about power capacity for van living:

Coming soon: LINK TO POWER VIDEO

Product: Power Panel (DIY Electrical Kit)

Step 8: Windows and Doors

Windows, frequently a big topic with numerous points of view (AKA opinions). Roost Vans personal opinion is windows all around, with insulated window covers and doorway bug screens. Reason? If we’re in a van, in a beautiful area, we want to see around while we are hanging out inside.

Some thoughts and common arguments:

  • Too much light while sleeping… Insulated window covers
  • Too much heat loss… Insulated window covers
  • Security… You have a front passenger and driver window that can be broken too.
  • I don’t want to be able to see outside… Okay, well that’s valid then.
  • I feel too exposed… Also valid, but window covers help alot.

We talk all about window placement and integration in this blog here!

Step 9: Heating, Cooling, and Climate

The first and most important aspect of managing the interior comfort in your box on wheels is ventilation. Vented windows paired with a vent fan is ideal and the minimum suggested setup for comfort on the road.

Reality:
Bad airflow = condensation, heat, and a miserable trip. And, just for fun we made this beautiful adornment to your vent fan. Check out the Roost Vent Fan Trim Ring.

After that, let’s talk Air Conditioning… Yes or No?

This decision will determine comfort. Read this blog here!

Step 10: Interior Systems (Beds, Cabinets, Storage)

Explore the full product ecosystem here: Roost Product Playlist

There are plenty of other products that we have in development that go in our in shop builds, getting fine tuned for DIY products. So, check out our YT Build Videos and reach out if you see something you like.

Key Products:

Everything mounts to our Smooth Rail Mounting System for maximum flexibility and security.

Step 11: DIY or Not?

Be honest. Why get something done faster and cheaper when you can do it yourself…? 🙂

If you’re still asking “where do I start?”, you may not be a DIY enthusiast. But, anything is possible if you put your mind to it, and we can help you on your journey. A lot.

Your options:

  • Full DIY
  • Hybrid (Roost products + your labor)
  • Full build

Want Help?

If you want to shortcut the trial and error and make sure your van gets done and out of the drive way, get a proposal for your build and book a spot in our Portland, OR shop.

If you want to move forward building your van yourself, checkout our products and mounting systems, and get busy. Our team of experts can help you along your journey.

Ready to elevate your van life? Visit us at http://roostvans.com and see how we can help you with your adventures!

Check out our other social channels here: https://linktr.ee/roostvans.com