Purpose Built for Adventure: Aluminum Profiles for Vehicle Upfitting
Aluminum Extrusions for Camper Vans: Purpose-Built Solutions for Modular, Durable Builds
Modern camper vans and overland vehicles are no longer built like one-off projects. Professional upfitters are designing repeatable systems—kitchens, storage modules, bed platforms, and wall-mounted components—that must install cleanly, perform reliably, and hold up to years of vibration and use.
That shift has made aluminum extrusions a foundational material for serious van builders. Not because they look industrial—but because they solve real problems related to weight, strength, fit, and long-term durability.
At Orange Aluminum, we manufacture made-in-the-USA aluminum extrusions and stock the profile sizes van builders actually use, allowing you to design around real-world constraints instead of forcing materials to work.
This guide explains how aluminum extrusions are used in modern camper van and overland vehicle builds, and how to select the right profiles for modular and durable systems.
Framing Systems for Real Loads in Camper Van Builds
When van builders search for framing solutions, they are typically solving a very specific problem:
How do I build a structure that is strong, adjustable, and repeatable—without welding, custom fabrication, or unnecessary weight?
For both professional upfitters and DIY builders, aluminum framing systems have become the preferred answer. They simplify installation, reduce build variability, and allow designs to be reproduced consistently—whether you’re building one van or one hundred.
6063-T5 Aluminum T-Slot Profiles for Van Framing
6063-T5 aluminum T-slot extrusions, often referred to as quad track, are a core structural component in modern van conversions. Their advantage is not just modularity—it’s the ability to standardize framing while scaling strength based on real load requirements.
Common Van Conversion Applications
T-slot aluminum profiles are commonly used for:
- Modular kitchen and galley frames
- Bed platforms and seat bases
- Vertical wall-mounted storage systems
- Drawer frames and slide-out trays
Because these profiles are widely stocked in common sizes, builders can design once and source consistently—reducing lead times and avoiding one-off materials.
View T-Slot Aluminum Profiles →
Profile Size Drives Structural Performance
While all T-slot systems use the same connection concept, profile size and wall thickness are what determine strength, stiffness, and load capacity. Selecting the right cross-section allows builders to design systems that are structurally sound without overbuilding.
Common Profile Sizes and Typical Uses
25mm × 25mm T-slot aluminum profiles are commonly used for:
- Cabinet frames
- Interior storage modules
- Lightweight wall and partition systems
30mm × 30mm T-slot aluminum profiles are often selected for:
- Primary cabinet structures
- Drawer systems and slide-out trays
- Mid-span framing where added rigidity is required
40mm × 40mm T-slot aluminum profiles are typically used for:
- Bed platforms
- Load-bearing seat structures
- Gear mounts and stacked modular systems
Using standardized profile sizes allows builders to maintain consistency across layouts while scaling strength only where needed.
Why Builders Rely on T-Slot Framing
T-slot systems bolt together, which provides advantages that welded or wood-framed systems cannot:
- Alignment can be adjusted during installation
- Designs can be updated without redesigning the entire structure
- Components can be reused and standardized across multiple builds
These profiles are commonly used by professional upfitters designing repeatable systems, but are equally accessible for experienced DIY builders.
Build a Modular Framing System →
Complementary Mounting & Securement Systems
Professional van builds rarely rely on a single system. Depending on load type and function, builders often combine T-slot framing with dedicated mounting and securement solutions.
Aluminum L-Track (Logistics Track)
Aluminum L-track is a heavy-duty cargo securement system used throughout vans, trailers, and utility vehicles. It provides continuous anchor points that accept:
- Tie-down rings
- Stud fittings
- Adjustable cargo accessories
L-track is commonly used for:
- Cargo and gear securement
- Floor and wall-mounted anchor zones
- Load-rated tie-down applications
Because L-track components are standardized and widely available, they integrate easily into repeatable build layouts.
Aluminum Strut Channel
Aluminum strut channel offers a modular mounting solution commonly used for:
- Shelving supports
- Electrical and conduit routing
- Equipment and accessory mounting
Originally developed for industrial and mechanical installations, strut channel is well suited for van builds where adjustability and long-term durability are required.
Lightweight and corrosion-resistant, aluminum strut channel allows builders to make changes without custom fabrication—an advantage in both production environments and evolving DIY builds.
Explore Aluminum Strut Channel Systems →
Designing for Strength, Consistency, and Scalability
Each system serves a distinct role:
- T-slot profiles provide modular structural framing
- L-track delivers load-rated securement
- Strut channel supports adaptable mounting needs
The most efficient van builds use these systems together—sizing each one appropriately and relying on consistent, readily available components to streamline builds and reduce friction over time.
Structural Aluminum Stock Profiles for Van Builds and Vehicle Upfitting
Aluminum angles and U-channels are foundational profiles in van conversions and commercial vehicle upfitting. They are used to reinforce structure, create reliable mounting surfaces, and finish exposed edges—often without adding complexity or custom fabrication.
These profiles offer a straightforward way to improve rigidity, alignment, and durability using consistently available components.
Aluminum Angle Profiles
Aluminum angles are commonly selected based on leg size and wall thickness, allowing builders to match the profile to the load and application.
Common Applications
Aluminum angles are widely used for:
- Reinforcing cabinet corners and structural joints
- Creating mounting flanges for panels, doors, and access covers
- Supporting shelving and work surfaces
- Tying plywood or composite panels into aluminum framing systems
Because angle profiles are available in standardized sizes and finishes, they are easy to source consistently—supporting repeatable layouts across multiple builds.
Browse Aluminum Angle Profiles →
Aluminum U-Channel Profiles for Van Panels and Cabinetry
Aluminum U-channels are commonly used in van conversions and vehicle upfitting wherever panel capture, edge reinforcement, and clean alignment are required. Their channel geometry allows panels to seat securely while maintaining straight lines and consistent spacing across the build.
U-channels are most often selected based on inside width and wall thickness, allowing builders to match the profile precisely to the panel material being used.
Common Panel Sizes U-Channels Are Designed to Fit
Van builders frequently search for U-channels sized for standard panel thicknesses, including:
- 3/16″ and 1/4″ panels – commonly used for wall and ceiling systems
- 1/2″ panels – often used for dividers, cabinet backs, and structural inserts
- 3/4″ panels – typical for cabinetry, drawer systems, and higher-load components
Selecting a U-channel with the correct inside dimension ensures a secure fit without shimming or adhesives, supporting faster installation and repeatable results across builds.
Common Applications
U-channels are commonly used for:
- Capturing and reinforcing panel edges
- Creating sliding or fixed panel tracks
- Aligning cabinet backs and divider panels
- Finishing exposed plywood or composite edges
U-channels simplify installation by acting as both a structural support and a finishing element, reducing the need for additional hardware or trim pieces.
View Aluminum U-Channel Profiles →
Selecting Profiles by Leg Size and Wall Thickness
For both angles and U-channels, leg dimensions and wall thickness directly influence stiffness, load capacity, and long-term performance.
- Smaller profiles are typically used for trim support, edge capture, and lightweight panels
- Larger profiles and thicker wall options are used where added rigidity or mounting strength is required
Selecting the appropriate profile ensures structural stability without unnecessary weight—an important consideration in mobile environments.
Performance in Mobile Environments
Aluminum angles and U-channels maintain dimensional stability under vibration, temperature changes, and repeated use. This makes them especially effective in high-traffic and high-use areas such as:
- Galleys and kitchen systems
- Storage compartments
- Doors, drawers, and service panels
By reinforcing stress points and maintaining alignment over time, these profiles contribute to long-term durability in vehicle interiors.
Design Reinforced Panel & Cabinet Systems →
Edge Protection and Finishing Profiles
Beyond structure and mounting, aluminum profiles play an important role in safety, durability, and finished appearance—especially in confined interiors.
Heavy-Duty Aluminum Corner Guards
In van interiors, exposed corners along walkways, bed platforms, and galley edges are subject to frequent contact and impact.
Heavy-duty aluminum corner guards feature increased material thickness and a generous radius to:
- Reduce injury risk in tight spaces
- Protect edges from dents, scuffs, and wear
- Extend the service life of cabinetry and furniture
These profiles are commonly used in commercial and fleet builds where durability and safety are priorities.
Aluminum Edge Trims and Pull Handle Profiles
Aluminum edge trims and integrated handle or pull profiles are used to:
- Finish exposed panel edges cleanly
- Improve durability at high-wear touch points
- Eliminate the need for added hardware on doors and drawers
Using standardized trims and handle profiles allows builders to maintain a consistent look and simplifies sourcing and replacement across builds.
Explore Edge Trims & Handle Profiles →
Designed for Consistency and Scalability
When used together:
- Aluminum angles reinforce structure and provide mounting surfaces
- U-channels capture, align, and finish panels
- Corner guards improve safety and impact resistance
- Edge trims and handle profiles enhance usability and appearance
These profiles are commonly used by professional upfitters designing repeatable systems, but are equally accessible for experienced DIY builders.
Selecting profiles by function, leg size, and wall thickness—and relying on consistently stocked options—allows builders to create systems that are durable, repeatable, and efficient to produce, whether for a single custom build or a scaled conversion program.
Why Made-in-the-USA Aluminum Extrusions Matter for Van Builders
When you are building systems—consistency becomes as important as strength.
Orange Aluminum aluminum extrusions are manufactured in the United States, providing builders with a level of reliability that imported or short-run profiles often cannot match.
Our domestic manufacturing supports:
- Dimensional consistency across repeat orders
- Reliable alloy quality and temper control
- Predictable fit across multiple builds and layouts
- Stable lead times and dependable inventory availability
For professional upfitters, these factors directly affect production efficiency, quality control, and customer satisfaction. For DIY builders, they reduce fitment issues and rework when designs evolve or expand.
Supporting Builders from First Build to Scaled Production
Orange Aluminum works with builders at every stage—from initial prototyping through scaled production—without forcing changes to established workflows.
We support:
- Independent camper van builders
- Overland and adventure vehicle outfitters
- Modular system and component manufacturers
Builders rely on Orange Aluminum for:
- Stocked profile sizes commonly used in van conversions
- Cut-to-length services that reduce waste and labor time
- Support for both one-off builds and repeat production runs
- Fast fulfillment from California-based operations
Because profiles are consistently available and dimensionally reliable, builders can design once and source with confidence—whether they are refining a prototype or maintaining continuity across a production line.
Explore Stock Aluminum Profiles →
Request Customization Services →
Build Smarter with Aluminum Extrusions
From framing systems sized for real loads to edge trims designed around common panel fits, aluminum extrusions allow van builders to create interiors that are lighter, stronger, cleaner, and easier to maintain.
Explore Orange Aluminum’s:
- T-slot aluminum extrusions
- Aluminum Strut Channel
- Aluminum L-Track
- Aluminum Corner Guards
- Aluminum Angles
- Aluminum U-channels
- Aluminum Edge trims
Or request samples and cut-to-length pricing to see how Made-in-the-USA aluminum extrusions can elevate your next camper van or overland build.
