The Best Tools for DIY Airstream Trailer and Camper Van Renovations
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Discover the essential tools you’ll need to tackle your own Airstream remodel! From metalworking and woodworking to plumbing, we break down the basics and share practical techniques to help you use these specialized tools like a pro.
Grinders (0:39)
For thicker aluminum, we prefer a corded grinder — it delivers more power and won’t drain the battery in minutes like a cordless one would. That said, a cordless grinder is a solid choice for quick cuts, thin aluminum, or smoothing out edges. It’s fast, efficient, and convenient for lighter tasks. Get our Corded Angle Grinder on Amazon.
Aluminum Cutting Techniques (1:11)
Old-school hand shears: These are a tried-and-true method for cutting aluminum. The color of the handles—green for left-cutting and red for right-cutting—determines the direction the metal will peel away. If you're making a full cut, the green-handled shears (left-cutting) will push the metal upward, while the red-handled shears (right-cutting) will push it downward. Generally, you’ll want to use right-hand shears when cutting counterclockwise on a curve and left-hand shears for clockwise cuts. Get the left/right shear combo on Amazon.
Double-cut shears: These are great as a quick and easy cutting method with less manual effort, though they don’t leave the cleanest edges. One thing to watch for is scarring — these shears can mark up the aluminum. To avoid unwanted blemishes on your final piece, lean slightly away from the material you’re keeping so any marks land on the scrap you’re throwing away instead of the piece you’re keeping.
Nibbler: This is another option that functions like a hole punch for metal. It’s especially useful for cutting curves but does leave a serrated edge. If the cut area will be covered later, this isn't an issue. Otherwise, you can smooth and refine the edge with a grinder — this is where a cordless grinder shines for quick shaping and cleanup. Get the Makita 16 Gauge Nibbler on Amazon.
Types and Uses of Rivets (3:12)
There are a variety of rivets that you’ll use in an Airstream build:
1/8” Pop Rivet: This rivet is strictly for interior applications and is not designed for structural or exterior use.
5/32” Buck Rivet: For exterior applications, we use a buck rivet, which is much stronger than a pop rivet and requires a different installation method. The process begins by placing the rivet into a pre-drilled hole, with Sikaflex applied between the joint for waterproofing and an additional layer on the rivet tip. The hole may need slight widening to allow the rivet to slide in.
Buck riveting is a two-person job. Sometimes, a light tap is needed to set the rivet in place. At this stage, the rivet is fully seated in the hole, but the back end remains uncompressed. This is where the bucking iron and rivet gun come into play. One person holds the bucking iron against the back of the rivet while the other operates the gun from the front, compressing the rivet into a strong, permanent bond. This is the only structural rivet we’ll be using on an Airstream.
Olympic rivet: If you can’t access the back of an exterior rivet, an Olympic rivet is an alternative—but it shouldn’t be used as a replacement for buck rivets in all cases. Unlike buck rivets, Olympic rivets don’t require a second person, making them easier to install for patches or repairs.
Installation involves pulling the rivet until it pops, leaving a protruding head. To smooth it out, you can cut it with dikes or feather it with a grinder, which helps it blend into the surrounding surface. However, Olympic rivets aren’t as structurally strong as buck rivets, so they should only be used when necessary.
Cleco pins are used alongside rivets to hold metal pieces together before riveting. Using Cleco pliers, you compress the pin, insert it into the hole, and it locks behind the metal. This acts as a temporary rivet, allowing you to test fit the alignment before applying adhesive and setting the final rivets. For a demonstration, check out the video example showing how Cleco pins secure two metal pieces by holding them in place before the final riveting process.
Sealants and Caulk (6:39)
Sikaflex is a premium waterproof sealant that provides a strong, durable bond once dried. It’s essential for sealing joints and ensuring long-lasting protection against moisture.
When it comes to application, Nate prefers a handgun, while Teo swears by his Milwaukee cordless caulking gun. The cordless gun speeds up the process by pushing out the product much faster, making it ideal for covering large areas efficiently. No matter which tool you use, the key is ensuring full, even coverage for the best results.
Mapping and Marking Your Rivet Pattern (7:30)
When marking up lengths and cut lines, a square and a Sharpie are your best tools for accuracy. For rivet placement, a rivet template gauge is invaluable — you can stretch or compress it to match different spacing needs. Once you’ve set the desired length, simply place a dot to mark where to drill, ensuring a clean, consistent rivet pattern.
Using Rivet Guns (8:46)
The Marson rivet gun is a solid choice for riveting, thanks to its interchangeable heads. Just remember—each rivet size requires a matching rivet head, so always swap to the correct one before starting your work to ensure a secure fit and proper installation.
Choosing Your Drill Brand (10:44)
We’re big Makita fans—we’ve got a lot of their tools. Sticking to one brand is great because the batteries are interchangeable, which makes things a lot easier. Mixing brands can cause issues with compatibility, and it just doesn’t work as smoothly. That said, we do make a few exceptions—like using a Milwaukee PEX crimper, which we love despite it being from a different brand. Get the Makita Compact Cordless 2-Pc. Combo Kit on Amazon.
Drills (11:15)
The first thing you’ll want to invest in is a good set of drills — I prefer having both an impact driver and a drill. The impact driver is especially invaluable for woodworking and setting screws. For basic woodworking, you don’t need a fully stocked shop setup. Hand tools can get the job done just fine these days, and tools like a track saw are a great alternative for precision cuts without taking up too much space.
Saws (11:33)
The Festool Guide Rail is a game changer—it can be clamped to any surface and features grooves and a tracking system that lets the Festool Plunge Cut Track Saw glide along, ensuring perfectly straight cuts. This setup is fantastic because it’s much more portable and space-efficient compared to a traditional bulky table saw. You can also extend the tracks by connecting them together, giving you up to 12 feet of cutting length, perfect for large projects like cutting plywood or straight-edging materials.
Another solid option is the Makita Cordless Miter Saw, which runs off of two batteries. It’s very precise and does an excellent job with trim work. This is a great alternative for getting a lot of your tasks done, especially if you need something that’s both portable and efficient.
Scribing (12:56)
Learning how to scribe is essential for Airstream renovations.
A compass is an essential tool for scribing and shaping wood or panels to fit snugly against a wall. Here’s how it works: position your piece of wood against the wall, adjust the compass width and trace along the surface. This gives you a precise cut line, allowing you to shape the piece to fit perfectly around curves. For actually making the cut, the most affordable option is a jig saw — it’s versatile and great for handling curved cuts with ease.
More Saws (13:53)
The most important tools you’ll need for your interior buildout are:
Jig saw: shop our recommendation from Bosch (available on Amazon).
Track saw: shop our recommendation from Festool (available on Amazon).
Chop saw: shop our recommendation from Makita (available on Amazon).
Routers (14:04)
A router is handy for adding character to your wood since you don’t want everything to have a sharp, square edge. We often use an 1/8-inch round-over often to create a clean, softened look.
This Makita battery-operated router is a great little tool—smooth, precise, and easy to handle—making it perfect for finishing edges without the hassle of cords.
Nailing (14:26)
When fastening materials together, you’ve got a few solid options:
Staples: shop our recommendation from meite (available on Amazon).
Pin Nails
Micro Pin Nailer: Perfect for holding trim in place while glue sets. This tool uses headless pins that leave tiny holes, making them nearly invisible. While it doesn’t provide much holding power on its own, it’s excellent for keeping pieces aligned until the adhesive fully dries.
PEX Plumbing (15:23)
Most of your plumbing will be PEX, and there are a couple of ways to work with it:
Manual Crimping — using an iCrimp PEX Pipe Cutter, you place it over the crimp ring and press until it fully closes.
Crimping via a Power Tool — makes the job much easier, though it’s more expensive. The end result is the same, but this method saves time and effort.
Essential PEX plumbing tools (get the PEX Starter Kit on Amazon):
PEX Piping
Pex Cutter: A must-have for clean, precise cuts on PEX pipe; affordable and easy to use
PEX Rings
PEX Fittings
Electrical (17:40)
Your basic electrical tools are simple. You’ll need:
Volt Meter: Essential for continuity testing to check if a wire is intact or if you’ve accidentally nicked it. Get the Fluke 117 Digital Multimeter on Amazon.
Wire Strippers: Get the IRWIN VISE-GRIP Wire Stripper on Amazon.
Crimp Tools: Available in different sizes; for jobs like battery cables and solar setups, a 1/8th gauge crimp tool works great. Get the iCrimp Wire Rope Crimping Tool on Amazon.
