Disastrovan: Chevy Astro Van Camper Project
Disastrovan is a a 1996 AWD Chevy Astro van that I turned it into a compact log cabin on wheels. This post covers how I built out the shelving system. No frills or fancy vanlife Pinterest boards here; just practical, field-tested design after ten years of DIY conversions.
I’ve built out two rigs before this one. With each version, one thing evolved more than anything else: storage. Specifically, how I used it, where I put it, and how to stop stuff from flying around the second I hit the road.
Three Core Shelving Principles
Every decision in this build came back to these three rules. Simple, but game-changing.
1. Build From Floor to Ceiling
Forget nightstands, countertops, or kitchen islands. The moment you drive, anything sitting on top becomes a projectile. In this van, every vertical inch counts. My shelves go from floor to ceiling, with lips or enclosures to keep things in place. It’s the only way to make a small van actually feel usable.
In this van, every vertical inch counts. My shelves go from floor to ceiling, with lips or enclosures to keep things in place. It’s the only way to make a small van actually feel usable.
2. Use Depth and Negative Space
Good van storage is more than just stacking boxes. In this build, I placed the front-most shelf from the driver’s seat, making sure it didn’t block my rearview. Behind that, I built depth; layered cubbies, back shelves, and enclosed drawers.
There’s also intentional negative space. Under the rear shelf sits the coolant-powered heater. Instead of boxing it in, I left it open to act as a drying zone or gear nook. Wet shoes? Toss them near the heater. Need a spot for camp chairs or fire pits? That open space handles it.
3. Everything Needs a Home
If it doesn’t have a place, it becomes clutter. I use packing cubes, Dyneema pouches, and zip bags to keep similar gear grouped together. My shirts live in an Eagle Creek Specter cube. Camera gear stays in a dedicated ICU. Rechargeables, cords, and toiletries each get their own kit.
When everything has a home, packing becomes easy. So does cleaning up.
What the Shelves Actually Hold
Here’s how the layout plays out in real-world use:
- Lower Shelves: Shoe storage and a shallow ICU for camera gear.
- “Junk” Drawer: A felt-lined slide-in tray for quick access gear like a battery bank, flashlight, lighter, and cables.
- Mid Shelf: Floating workspace; I haven’t dedicated it to anything permanent yet, but it’s great for layers or trail snacks.
- Bookshelf: Built with tension fit so books never fall out. Push back, then lift to remove.
- Rear Panel Compartment: Covers the wheel well and holds reflective triangles, jumper cables, trekking poles, and emergency gear.
Loadout: What Fits in the Shelving System
I did a mock packout to see how much the shelves can handle:
- Therm-a-Rest Z Seat
- Backpacking meals (2–3 days)
- Sawyer Squeeze kit with Evernew bottles
- Hyperlite Southwest 55 pack
- Clothes (rolled in packing cubes)
- Two Marmot Trestle Elite sleeping bags
- Jetboil MiniMo + fuel + stand
- GSI Infinity Mug
- Stakes (MSR Groundhogs in Dyneema bag)
- Trowel and TP kit
- Rechargeables and cords
- Ghost Whisperer 2 puffy
- Toiletries (Tenba Duo cable bag)
- Sea to Summit Ultralight Deluxe Pillow
- NeoAir UberLite pad
- Zpacks Duplex tent
- Umbrella, gloves, and extra layers
Everything fits. Nothing rattles. No wasted space.
Final Thoughts: Make It Practical First, Pretty Later
This isn’t a flashy build, but it works. The goal wasn’t aesthetics. It was easy access, clean storage, and a layout that made sense for daily use. After years of trying countertop-style designs, I finally landed on something that feels livable.
If you’re building out a small or midsize van and you want fast access, a clean layout, and no loose gear flying around—this style of shelving is worth replicating.
