Camping box project

The Tardis factor (interiors, awnings, roofs etc)

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silverbullet
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Camping box project

Post by silverbullet »

I while ago I bought three sheets of Morland's finest 15mm lightweight faced ply, after a fit of good ideas and sketching out a concept.
I'm not one for fitted furniture in the bus, much prefer a "field kitchen" in the back (it suits my height) that keeps smells outside and can be demounted as required, but there us never enough counter space! So I came up with the idea of a pair of 600mm cubes that will take a gas twin burner, Cobb and all the rest of it. Internal drawers, a slide out tray cooker and a chopping board/prep space etc plus the large area on top for "service!!!" and two side hinged front doors that will act as a wind break.
Basically a kitchen in a box (but not an American chuck box)
I'll use this topic as a notepad.

Drawers: I have seen Blum Tandembox used in an expedition trailer and they have a lifetime guarantee. Pressed steel, 30kg capacity, nice.
https://www.drawerboxes.co.uk/blum-tand ... 02x2276411" onclick="window.open(this.href);return false;

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Re: Camping box project

Post by DoubleOSeven »

Not one for fitted furniture either, will follow with interest. Currently stand outside and pop the gas burner on the cooler. Offers a nice height but the back seat and buddy box do become the work surfaces, so room for improvement personally. I just prefer the option to remove everything internally when not being used. Rambling on ... but watching this thread.
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Re: Camping box project

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Yes I got tired of the "functionally adequate" pair of Really Useful Boxes but whilst watertight and waterproof, I was forever lifting a lid to get the thing I had forgotten or not taken out to avoid the spread of camp dross.
Also not very flame-tolerant...no accidents so far but just a matter of time.

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Re: Camping box project

Post by silverbullet »

One of my working sketches, the idea of dividing the box into two was to make them each a manageable weight when full.
I have some flight case handles for lifting duties.Image

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Re: Camping box project

Post by Jim San »

I was sketching loads of ideas like this when plannign my new apporach.

A split cube opening along a diagonal to create a higher work surface, lift up and lock flaps either side for space to put stuff - and indipendant 4 telescopic drop 'n' lock legs to save faffing with uneven and rocking surfaces out on the grass.


3 sheets ! That's a lot. I used 3.5 for a 'kitchen area' and unit where wardrobe usually goes.
It's great stuff to work with, cuts beautifully and edges finish nice
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Re: Camping box project

Post by silverbullet »

I overbought the materials, because I knew I wasnt going to be near Morlands for a while ;)
But the original design as drawn (with hinged tops, dividers etc required well over two sheets. It adds up fast when you have to put backs and bases on boxes that fitted units dont need.
A rethink means there's now spare material for a rear bench kickboard, a hinged shelf/picnic/brew table, maybe a cab cubby box.

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Re: Camping box project

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PS any tips for chip-free cutting gratefully received!
I have a Skilsaw 1300W and a 48t laminate blade, but it's done a little work (not loads) and will be working on trestles/site table.
I'll radius the corners with a "compression" type cutter bit and slot the edges to take standard rubber trim.

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Re: Camping box project

Post by Titus A Duxass »

silverbullet wrote:PS any tips for chip-free cutting gratefully received!
I have a Skilsaw 1300W and a 48t laminate blade, but it's done a little work (not loads) and will be working on trestles/site table.
I'll radius the corners with a "compression" type cutter bit and slot the edges to take standard rubber trim.

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Position the saw do that the blade enters the board through the laminate and not exits through the laminate.
Affair good results can be got by taping along/over the cut lines with frog tape.

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Re: Camping box project

Post by clift_d »

Most flight cases are made with faced 9mm Wisaboard, so if you’re using 15mm plywood you’ll need to be careful in terms of overall weight - particularly once you’ve added in the weight of the contents.

For flightcase fittings you could look at places like AdamHall
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Camping box project

Post by clift_d »

To avoid splintering your plywood you can either cut from the back face so the circular saw blade teeth are cutting ‘into’ to the finish face and all the chipping happens on the hidden back face, or alternatively cut along your line with a Stanley knife to sever the grain in the top ply and then carefully set up your saw to cut just outside the line.

Openings in the ply are probably best formed using either a router, or a jigsaw with a laminate blade that cuts on the down stroke.
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Re: Camping box project

Post by Jim San »

silverbullet wrote:PS any tips for chip-free cutting gratefully received!
I have a Skilsaw 1300W and a 48t laminate blade, but it's done a little work (not loads) and will be working on trestles/site table.
I'll radius the corners with a "compression" type cutter bit and slot the edges to take standard rubber trim.

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It cuts very very easily. The laminate is thin and not brittle. I used my hand circ saw (with the original well used blade) and a jigsaw with regular wood blade. The laminate is both sides (as you know) and cutting either side gives same result.
Taping or pre-scoring is not required.

The edges plane quite nicely - as with ply you do get fluff on end grain - but long grain and face plane nicely to remove machine marks.
Face has fairly low resistance to impact damage. Soft faces in vice needed etc.
I'll dig out an off cut if I can get to back of shed and photo the edges.

Factory edges though - they can bite - I got sliced accross 4 fingers unloading from roof rack
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Re: Camping box project

Post by silverbullet »

Thanks all!
To clarify: 15mm lightweight poplar ply, laminated both sides.
Redesign to incorporate Blum internal drawers will eliminate at least one 600mm square divider/shelf from each box, plus some smaller pieces, probably getting on for 0.5m² per box.
Gas bottle is easily demounted for loading.

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Re: Camping box project

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Further thanks to JimSan for a welcome technical chat message session this evening.

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Re: Camping box project

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Sidebar note: Jackson's Leisure supplies.

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Re: Camping box project

Post by rollercoaster »

My Danbury refit is using as much of my "resources" as possible,
some bits that have been resources for far too many years,
so its way past time for them to get used up.

Just about to go buy some plywood panels just to line the van,
and the same idea is having the whole lot able to remove and work elsewhere.
Something I am struggling with in my head is the securing of it all,

My design is a long low box base fixed at the front and back (wheel arches)
and various versatile things that fit and move around on top.
It could be a toolbox one day, and a cooker the next,
or a cargo to transport and no regular interior at all.

The long box is bed height, so when its possible its a full width bed.
All a work in progress so looking forward to this thread.
Useful to know about Morelands, not that I am rushing to spend money.

Another trick I use when cutting or drilling, where its going to chip,
and often where might have to use a tool or in a position where it chips,
is clamp up sacrificial surfaces one or both sides and cut through them all.
Hope thats clear enough description of how to do it.

Characteristically my new interior is solid ply and well chipped edges, sanded..
And it needs plenty of D rings all over the place to hold things strapped in place.
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