Upholstering panels in your camper van adds more than just visual appeal—it provides insulation, sound dampening, and a cozier feel compared to hard surfaces like paint or laminate. In this guide, you’ll learn step-by-step how to upholster van panels using Marathon fabric, 3M adhesive, and essential tools. Whether you’re customizing your build or upgrading your interior, this guide covers everything you need.
Why Upholster Your Van Panels?
Upholstering your van interior has both functional and aesthetic benefits:
- Reduces road noise
- Adds thermal insulation
- Softens the look and feel of the interior
- Covers plywood for a cleaner, finished appearance
- Protects panels from moisture and wear
Materials & Tools You’ll Need
Upholstery Materials
- Marathon Fabric – Heavy-duty tweed-like fabric, resistant to runs and durable for van life
- Foam padding – Optional layer for added cushion and texture
- DynaLiner – For noise and heat insulation on metal surfaces
- Energy Shield or ABS plastic – Used for trim transitions or panel reinforcement
Tools & Supplies
- 3M Super 77 Spray Adhesive – Ideal for fabric and panel bonding
- OLFA Utility Knife – With breakaway blades for precision and safety
- Latex Paint (Optional) – Use for moisture-prone panels like sliding doors
- Plywood or Baltic Birch Panels – Half-inch, 7-ply recommended
- Workbench or Plywood Table with Sawhorses – For panel layout
- Clamps and Drill Jig – To pre-drill perfectly aligned holes
Step-by-Step Panel Preparation
1. Choose Your Fabric and Order Extra
- Use a supplier like Perfect Fit to get free samples
- Select texture, color, and pattern based on your build theme
- Order 20% extra fabric to account for layout adjustments, errors, or new ideas
2. Prep Your Wood Panels
- Sand edges and surface smooth
- Paint with latex (optional) to prevent water damage if exposed
- Drill holes using a jig to align with 80/20 or wood framing
- Test-fit the panel before applying fabric
3. Use Quality Wood and Store It Properly
- Ideal: Baltic birch
- Acceptable: High-quality sanded plywood from Lowe’s or Home Depot
- Let your wood acclimate to your shop to prevent warping
- Always back unsupported panels with framing (80/20 or wood)
Applying the Adhesive
4. Prep Your Workspace and Materials
- Ensure your layout table is clean and at a comfortable height
- Use nitrile gloves to keep your hands clean and avoid sticking
- Use proper ventilation or a respirator if in a closed space
5. Apply 3M Super 77 Spray Adhesive
- Shake well before use
- Hold can 10–12 inches away
- Apply light, even coats in alternating directions
- Spray both the panel surface and the fabric
- Let each coat dry 1 minute before applying the next
Pro Tip: Use 3–4 coats for strong, long-lasting adhesion. Avoid wet, “boogery” sprays that lead to weak bonds.
Upholstering the Panel
6. Align the Fabric and Apply
- Center the panel on the fabric
- Press gently from the middle outward
- Smooth out air bubbles as you go
7. Wrap the Edges Cleanly
- Leave 1.5 inches of fabric around all edges
- Pull fabric taut over the edge
- Cut 45° angles at corners for a clean fold
- Use your thumb to press into edges and create definition
- Secure fabric on the back with a light adhesive pass
Mounting and Finishing Touches
8. Reinforce Your Panel Mounting
- Mount into 80/20 extrusions or rib nuts in the van
- Ensure framing is strong enough to prevent warping
- Mark hole locations on the back before covering with fabric
9. Cut Open Mounting Holes
- Use a razor to carefully make “X” cuts in the fabric where mounting bolts go
- Avoid full circles; this prevents fraying
Real-World Example: Thomas’s Van Panel
In this build:
- Panels were mounted on the driver’s side rear of a Ford Transit
- Used Marathon fabric for a desert-style texture
- Back side was also painted for extra protection
- Matching panel used ABS plastic and bungee netting for rear storage
- Panels were secured into 80/20 framing and rib nuts
The result was a clean, professional finish done with affordable tools and a DIY mindset.
Watch the Full Tutorial
Want to see the full process in action?
▶️ Watch the Van Panel Upholstery Video
Need Help with Your Van Build?
Odyssey Custom Vans builds handcrafted adventure vans designed for comfort, self-sufficiency, and style.
We offer:
- Custom full builds
- DIY consultations
- Expert advice on solar, electrical, water, insulation, and more
Click here to contact us and tell us your van life story.
Let us know where you’re headed, and we’ll help you build the rig to get you there.
