Don Not Buy Van Flares: You May Not Need Them

When I started my van build journey, one of the first things everyone seemed to suggest were van flares. The idea was simple: if you wanted to sleep width-wise in your van, you needed flares to get those extra inches. For someone over 6 feet tall, this seemed like a non-negotiable. Here you can learn more about van flares. But as I dove deeper, I realized there might be another way, a more integrated solution that could save both money and the hassle of major exterior modifications.

I discovered that with careful planning and a bit of custom craftsmanship, it’s entirely possible to create comfortable bed bump-outs inside the van, even in a Ford Transit, which has a stock interior width of around 70 inches at its widest. The goal was to extend the sleeping area enough for someone tall—around 6’2″—to lie across the width of the van without having to sleep at a significant diagonal or bend their knees excessively. While external flares offer the most generous width, this custom internal approach aimed to maximize the available space, creating a bed width of approximately 6’0″ to 6’3″ (72 to 75 inches) with the bump-outs. This not only maximized the interior living space, allowing for a fixed dinette, a large kitchen, and even an indoor shower, but it also kept the van’s exterior looking clean and subtle.

The process involved some clever engineering. First, the bed height was carefully chosen to ensure comfortable headroom when sitting up. Then, the bump-outs themselves were constructed using sturdy materials like Baltic birch plywood and reinforced with aluminum supports. The key was to build these boxes outside the van, allowing for precise shaping to accommodate the van’s subtle interior taper, which can vary by a few inches from front to back. Crucially, while I chose to integrate windows into my bump-outs for light and ventilation, it’s absolutely possible to build these bump-outs without adding any windows, maintaining a solid van wall.

If you choose to add windows, they can be a crucial part of the design, cut high into the van’s panels and integrated into the bump-outs. This brings in light and air without compromising the structural integrity of the custom build. Careful measurements and even wax paper templates are used to ensure perfect window placement. Inside the bump-outs, recessed LED lighting can be installed for both practical and ambient illumination, with switches and charging stations conveniently located by the bed.

A significant consideration was moisture management. In a small van environment, condensation can be a real issue, especially under a mattress. To combat this, I learned the importance of drilling many holes in the bed platform to allow for constant airflow, preventing mold and mildew buildup. The plywood was also poly-coated for extra moisture resistance, and the entire structure was securely anchored to the van walls.

Ultimately, while building these internal bump-outs required a good amount of effort and attention to detail, the payoff was immense. The van gained a spacious and comfortable sleeping area without the need for expensive exterior flares, allowing for a more versatile and livable interior layout.

Pros and Cons of Internal Bed Bump-Outs

Cons:

• Complex Build Process: Creating internal bump-outs is a custom carpentry project that requires precision, patience, and some DIY skills. It’s not a simple bolt-on solution.
• Limited Space for Very Tall Individuals: While internal bump-outs can provide enough space for someone around 6’0″ to 6’2″ to sleep width-wise, it will be a very tight fit for someone at the upper end of that height range to lie perfectly straight. If you are over 6’2″ or desire more personal space to move around without touching the walls, external flares offer superior width (often up to 80 inches or 6’8″).
• Insulation Challenges: Integrating insulation into these custom shapes requires careful layering and sealing to maintain thermal efficiency, especially in cold or hot weather. This can be more intricate than insulating a standard van wall.
• Requires Cutting Van for Windows (if desired): While you avoid cutting for flares, if you do choose to have windows in your internal bump-outs for light or airflow, you will still need to cut openings in the van’s side panels. If you decide not to install windows, this con is completely avoided.

Pros:

• Save Money: Internal bump-outs can be a budget-friendly alternative to exterior flares. A set of flares typically costs $1700–$2,500, and with paint and professional install, the total can reach $4,000+. Building internally can be a much more budget-friendly option.
• No Exterior Cutting (for Flares): You avoid cutting large, complex holes in the van’s exterior for flares, which can be a daunting and irreversible process.
• Maintain Van Aesthetics: The van’s exterior remains unchanged, which is great for a stealthier look or if you simply prefer the factory appearance.
• Integrated Design: Internal bump-outs can be seamlessly integrated into your overall interior design, offering a more custom and cohesive feel.
• Flexibility with Windows: You can choose to install windows within the bump-outs for light and ventilation, or opt to skip windows entirely, simplifying the build and avoiding additional exterior cuts.

For anyone over 6 feet tall who prioritizes sleeping completely straight and needs good insulation for diverse weather conditions, traditional flares might seem like the obvious choice. However, as my experience shows, a thoughtfully designed internal bump-out can provide a comfortable, cost-effective, and aesthetically pleasing alternative that still allows for a viable, width-wise sleeping arrangement for those around 6’0″ to 6’2″, even without the added complexity of installing windows.