Post by reliantscimitar on Jan 5, 2017 17:54:54 GMT
A few more jobs done today.
I have cut and fitted 4 supports for the upper roof side trims. They are now bonded in but not sure if they will take as its been freezing all day.
Made and fitted the frame to support the front of the upper front cupboard and covered it with 9mm ply. This will then be covered with 3mm faced ply and the hole for the door will then be cut.
The door will be made from a lightened 9mm ply core covered each side with faced ply to give 15mm thickness which is just right for knock in edging. This panel and door will be finished of the van and fitted as a complete unit.
I have also made hard board templates for the side roof panels. Not sure if these will be faced ply or carpet lined yet.
Have decided to fit a Heki roof vent to give more light and ventilation.
Post by reliantscimitar on Jan 15, 2017 13:46:41 GMT
just thought you may me interested in how I make the doors.
I start with a 9mm ply board, cut it to size with 75mm diameter rounded corners.
I then cut two facing panels from 3mm faced ply.
One of these is then bonded to the core with contact adhesive.Once this has gone off I use a flush trim bit in a router to trim it to the profile of the door.
The next next facing panel is then bonded on and again trimmed flush.
The panel edge is the sanded to get rid of any rough bits.
Next job is to cut a groove with a 1mm slot cutter in the router taking care to get the groove central.
Last job is to fit the knock in edging being careful not to damage the panel when fitting the edging.You only get one chance to fit the edging as when yo pull it out it breaks up the ply and opens up the slot. Use a heat gun on the corners to get the edging to bend nicely.