Interior Refit where to get materials!

Post by **ali thommo** » 03 Aug 2008, 21:31

Hello, i am about to take out the crappy laminated chip board interior that breaks and chips and soon looks awfull, i want to replace it with a 15mm laminated plywood, i think this is the best thing to rebuild out of and has more strengh compared to chip board. I wanted to finish this with a T shaped edging strip. Two questions:
1) is there a bit to go in the router that will cut the groove in the plywood to take the strip? (only just got router and know little about them!)
2) does anybody know where to get this type of laminated plywood i have found a place that is way to far for me to pick up and they dont deliver, i assume lots of people must have rebuilt there interiors on here and was hoping someone could poor some knowledge onto these pages!

Any suggestions on better wood to use or the downsides of this would is, as allways much appreciated - thanks!

Post by **AngeloEvs** » 03 Aug 2008, 22:01

You could use a router with a 3mm bit but many conversions use 4mm veneered ply and cut the shape of each panel twice. An inner section is usually made up of 3mm material and just smaller than the outer panels and then all three bonded together to give the slot into which the plastic edge slots. More recently, to reduce the weight, the inner section is made of strips and bonded close to within 4mm of the edges to form a 'hollow' panel and that would be my preferred method of construction. 3mm veneer and plain for motorhomes are available from:

http://www.rainbowconversions.co.uk

download the on line catalogue and have a browse.

All the best

Website · Post by **CovKid** » 03 Aug 2008, 22:06

I'm actually doing exactly what you're doing as the chipboard stuff weighs a ton. I'm going for ordinary plywood which I'll then varnish using a plastic type varnish rather than yacht varnish. Never thought about routing out for corner trims.....

I made a DIY chipboard interior as a kind of prototype for layout and having used it I can see where the changes are needed. I left a nice gap behind drivers seat (3") which is great for storing a collapsible chair or table. I shall be keeping that facility as it worked well. Buddy seat is bit I have prob with as its difficult to make comfortable back against passenger seat.

Post by **ringo** » 03 Aug 2008, 22:07

AngeloEvs wrote:You could use a router with a 2/3mm bit but many conversions use 3mm veneered ply and cut the shape of each panel twice. An inner section is usually made up of 2mm material and just smaller than the outer panels and then all three bonded together to give the slot into which the plastic edge slots. More recently, to reduce the weight, the inner section is made of strips and bonded close to within 4mm of the edges to form a 'hollow' panel and that would be my preferred method of construction. 3mm veneer and plain for motorhomes are available from:

http://www.rainbowconversions.co.uk

download the on line catalogue and have a browse.

All the best

I didnt understand a great deal of that but feel i need to bookmark it

Ringo

Post by **AngeloEvs** » 03 Aug 2008, 22:13

Ok, imagine a cheese butty, you lift the top slice of bread and find that the cheese has been cut into narrow strips and placed close to the edges but the middle of the sandwich has naf all in the middle.

You probably seen em on motorway services at a tenner each!

Post by **ali thommo** » 03 Aug 2008, 22:46

Great information AngeloEvs thanks, i am keen on keeping the weight down so i like the idea of sandwiching the wood together and adding a fake lip to the front to make it look fuller, as long as the whole sideboard didnt flex! Ive enclosed an image to confirm im getting the right idea, The link you have attached is the place i had already looked at but they dont deliver! Thanks tho.

[IMG:587:376]http://i187.photobucket.com/albums/x90/ ... is/Ply.jpg[/img]

Hiya CovKid, what width of ply are you going to use? Is your ply going to be laminated or are you going to use a hard finishing varnish over a painted normal ply surface? Go for the edging strips they give it that robust finish!

Post by **AngeloEvs** » 03 Aug 2008, 22:51

almost, see my drawing update!

Post by **ali thommo** » 03 Aug 2008, 22:55

Thats great saves money and weight!

Just two things are 8mm t shaped edge strips readily available and i take it that the lug that pushes in the reccess is allways 2mm?

what sort of glue do you use to bond the three layers and do you use screw on the "fake lip" or is glue enough?

thanks again!

Post by **ali thommo** » 03 Aug 2008, 22:57

Thats great saves money and weight! i take it you build a timber frame to reinforce and attach the sheets to, and if so is it just a 1x1 or 2x1 type frame?

Just two more things! are 8mm t shaped edge strips readily available and i take it that the lug that pushes in the reccess is allways 2mm?

what sort of glue do you use to bond the three layers and do you use screw on the "fake lip" or is glue enough?

thanks again!

Post by **AngeloEvs** » 03 Aug 2008, 22:58

hang on a mo, I will do a drawing! The industry standard is 4mm with 3mm infill followed by 4mm + 1mm veneer face =12mm Total

Post by **ali thommo** » 03 Aug 2008, 23:02

Ok thanks! may have to see it in the morning!

Post by **AngeloEvs** » 03 Aug 2008, 23:07

Use PVA, available from any DIY store (Band Q), no screws just G-clamp and leave to set.

here is the drawing,

[img:350:118]http://muchos.co.uk/members/Angeloevs/edge.jpg[/img]

The inner 3mm strip/infill (not 2mm as previousley stated) can be any suitable material, even hardboard or 3mm MDF, tap T-edging into place using a mallet, (must have some radius on corners!). The standard thickness of panels used in most current leisure conversions is 12mm or 15mm and the T edging should be available in these widths but check first for availability. The edging should slightly protrude if possible but not essential. Dont forget to infill any area that will have items that will compress the panel such as door catches,etc. Get a courier to deliver if you have probs getting 3mm lightweight veneer, worth doing!

Alternatively, these doors were missing when I purchased my van. They are hollow, made from 4mm MDF and 3mm ply for the infil (cheap!), they are not veneered............they are emulsion. Three coats, flatted down between coats 1and 2. Hard wearing, any colour I like, easy to wipe and touch up if they get a slight chip. In fact......don't like the colour any more so doing them in a nice pastel blue. I personally do not like too many patterns in a small space and love the understated Westy interiors.

[img:500:375]http://muchos.co.uk/members/Angeloevs/doors190.jpg[/img][/url]

Post by **ali thommo** » 04 Aug 2008, 17:53

Thanks alot for the advise AngeloEvs! Now i need to go through the intense task of working out where i want what draws will have to find some pictures online! And then designing the 1x1 timber frame! Cant believe PVA is strong enough, but if you say so!

Post by **AngeloEvs** » 04 Aug 2008, 18:02

PVA is plenty strong enough for construction of the panels, should clamp to achieve max. strength of joint and leave for several hours. If you are building a frame then right angle brackets and screws will be needed to attach panels to the frame (not PVA). For ideas on interiors go here:

http://www.camperinterior.webfotos.co.u ... mes_2.html

Best of luck and do lots of drawings....its the old 6 P's........perfect planning.........prevents....

Post by **ringo** » 04 Aug 2008, 19:27

AngeloEvs wrote: [img:500:375]http://muchos.co.uk/members/Angeloevs/doors190.jpg[/img]

They look sweet!

How cool is that. Paint! Nice work...

Ringo