After lining the van with Plywood, there were still some awkward edges which were filled this week with wood filler. This was fairly easy to do and should make carpeting much simpler without jagged edges to consider. The biggest place to fill was above the side door which had to be strengthened as it will become a bed support…
I had decided to fit a bunk bed stretching out from above the van cab. I was limited to the height of the bed by the sliding side door and the window on the opposite side so head room was going to be tight. After a brief mock-up though, I decided it would be comfy enough for me and set to work creating a pillar each side to support the bed on. Due to the curvature of the van sides, one of the pillars would need to flex quite a large angle before being fixed in place. To get round this I used several thinner strips of ply which were bent and fixed together with wood glue. This curved beam could then be screwed in place. After a quick strength test, I fixed the timber beams which would take the majority of the load and then secured these in place.
The result was very solid but the gap to the roof of the van was going to be very tight indeed!
In future: "measure twice, cut once".
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