Finishing Up The Build

It has taken awhile, but the list of tasks is shrinking. Especially the tasks that require lumber and painting. The important items are complete (cabinets, bed, electrical) and the loading and securing gear is up next. I figure the best way to test if I’ve forgotten anything is heading out on a trip.

Curtains added for nighttime privacy.

Humans inside, mosquitoes outside (I hope).

Coffee mug - check!

Storage boxes over the wheel-wells are completed. Plenty of space to store stuff behind the sliding doors.

Fastest Year Ever

It is hard to believe that a full year has passed since I began the van build. If I have a large shop that would have enabled working through a Michigan winter, I’d most likely be done. I didn’t really get anything done from November to late March.

We finally have turned the corner on weather so that all of the outdoor building activities can be accomplished (present rainy excluded).

As a reminder, this was the starting point - an empty metal box.

The current build is very close to being camp-ready. I even placed the new Pendleton wool throw on the bed. Looks nice and adds a little splash of accent color (their Yakama design).

Up next is building boxes over the wheel wells in the rear storage/garage area under the bed. I’ll also add some charging ports and lights for things like air pumps or even a 12V cooler, if I decide to travel with one. At least to start, I’ll just use I.C.E. technology.

More van parts are currently being primed and painted to finish up the storage area, This also will add another layer of soundproofing (less road noise). There is a lot of storage space back here, which I’m sure will fill up.

Does It Look Like A Camper Yet?

Day by day, progress is being made. I still have quite a list of tasks to complete, but it is nice to pause for a moment. As of today, I have all of the electrical circuits connected at the fuse panel and just a couple more plugs or lights to attach. I need to finish a couple walls sections and storage bins so there is a place to attach those things to.

Also interesting to note that as of May 20th, my furnace is still running. Which means it has not gotten predictably warm outside yet. Maybe next week…? That would be nice.

w00t!

I’ve been waiting for this install all Winter. I had the upper cabinet frame ready, the door was built, painted and ready weeks ago. Yesterday I installed the IKEA Utrusta hinges (door lifters), which are very slick. They open smoothly and hold the door panel up by the ceiling when open. They also close softly with no latches required. I have a little bit of priming and painting inside the cabinet to complete, but this feels good to be done with.

I have a similar (but wider) cabinet to install above the bed at the foot end, so hopefully that will go faster and smoother, based on getting the first one done. Less fuss on the 2nd one, for sure.

Almost Another Completed Cabinet

As I inch towards completing another cabinet, I am reminded of the in-the-van, out-of-the-van pattern that develops when building one-off furniture. With each change or step, I need to recheck fitment in the van. I also need to have attachment points designed that allow for this, as well as methods to fully secure the furniture once complete.

The sink cabinet is a bit heavier than the previous cabinet. It will hold water jugs and also include a folding counter top extension and a step for climbing into the bunk. All this requires sturdier panels, which will adds some weight.

I should be able to do one last sanding in the morning and begin priming and painting. Thankfully the weather has improved enough that I can do the in the garage.

Working Outside

Sometimes things line up. A day off + nice weather + new supply of lumber means I will get something done. I moved my working platform outside, since the goal today was to cut all the plywood down to small pieces needed for the next cabinet project.

While it looked nice out, it wasn’t quite as warm as I had hoped. But I added a layer and closed the garage door so all the sawdust wouldn’t blow back inside. Swirling winds had the dust going every direction.

All of the sheets and framing material ready to go. The sink arrived today as well!

The top and bottom cabinet carcass frames are done, while the cabinets side panels are glued and being pressed together. I used two 1/2” sheets for each side so the cabinet will be sturdy. I learned from previous cabinets that the 1/2” plywood is too thin by itself to attach materials to, hold screws well and resist warping.

After a day of cutting with the new track saw, I am completely impressed by how easy it is to make very straight cuts now. I think I watched a dozen review videos of all of the different saws. Like most tool choices, you can decide to spend infinite dollars or be realistic and choose a budget based on how often and for how long a tool will be used. I bought the WEN corded track saw which I think is pretty near the least expensive choice. I added a 48 tooth blade. The saw has worked perfectly. My only regret is not buying it last year. Live and learn.

Time To Make Sawdust

Since I have more cabinets to build, I decided to get a track saw so that my panels and doors have a chance to be closer to perfect. Today I cut door panels for the upper cabinets. I wish I would have purchased this earlier. I don’t have a table saw (nor do I want one), so breaking down plywood was much harder to do accurately.

I added a sacrificial 4’ x 8’ foam sheet, so now I have plenty of work surface to break down a whole sheet of plywood quicker, safer and more accurately.

And some nice weather came along, too. I feel like the freezing weather may finally be in the rearview mirror.