Dai Syncro's interior build (with photos)

[uniB]

Through a bizarre coincidence, Dai found out about the new Dubteriors camper van interior business I have been plotting, having visited a friend on mine's house to fit some locks - although we'd briefly met before Dai didn't know about the whole interior building thing. We met up and over the last few months we've been planning what will be a rather special interior which will hopefully match the quality of the rest of the van. After a few set backs with blown head gaskets and the like, Dai's van has finally arrive with me and the build is getting going. Dai suggested I document the build on the forum (I think he just wants to keep an eye on me and make sure I'm getting on with it )

The design is a little unusual with the van having an outside side hatch which Dai wanted to access from the inside as well, and space was needed behind the cupboards to store stuff. The cupboards will be built from a collection of solid and veneer maple, stainless steel shiny bits and a wenge veneered worktop. Just to make it more complicated it has a number of curved laminated bits.

Plan is to get it all done by the end of June so it can be shown off at a few shows.

So here are a few pics...

The van in its new home for the next few weeks...



All stripped out, first job is to line out in silver lining carpet from Mega Van Mats



The old hob will be reconditioned and used in the new build



And here's what we're going to be building...







So far I've figured out I'm probably going to get a bit fitter climbing in and out of the thing, and the gap above the wheels make an ideal place to stand your cuppa tea!

[Drunk Aardvark]

This is going to look excellent. I need an interior for mine at some point!

[danmetallic]

Looking forward to seeing this!

[armyphil]

I've got a Chubb on watching this build

[Dad]

Sounds great! Watch those wenge splinters!

[Rogue Trooper]

Wow that brilliant!

[scottbott]

that should look good,cannot wait to see it

[Dai]

I think he just wants to keep an eye on me and make sure I'm getting on with it )

Youve got me sussed Dav

[Plasticman]

seen a few folk work with wood, beats me, its the work of the devil,dont know how you do it
mm

[uniB]

Well maybe I could trade you some of my woodworking skills for some metal joining ability - my welding is a constant source of disappointment to me

seen a few folk work with wood, beats me, its the work of the devil,dont know how you do it
mm

[uniB]

They're quite evil those wenge splinters, I've had my first one already - they don't come out without a fight!

Sounds great! Watch those wenge splinters!

[clift_d]

Hardwood splinters are always complete bar stewards - only thing worse is metal splinters.

[Plasticman]

Well maybe I could trade you some of my woodworking skills for some metal joining ability - my welding is a constant source of disappointment to me

seen a few folk work with wood, beats me, its the work of the devil,dont know how you do it
mm

like wise, will keep it in mind
mm

[jes*b]

Hi. This is going to be good, I'm interested in how you are going to curve the wood ? Ply laminated over formers? What glue are you going with? Cheers Jes

[uniB]

Thanks Jes,

I'll get some photos of the curved bits being done - I'll be using a flexible ply over formers - the larger ones will be dense polystyrene block and hte smaller ones will have an mdf former which I've had CNC'd. I have a vacuum veneer press which will be getting used for all these curved sections and the regular veneering. I'll be using Cascamite glue and crosslinked D3 PVA for the curved bits.

Cheers
Dav

Hi. This is going to be good, I'm interested in how you are going to curve the wood ? Ply laminated over formers? What glue are you going with? Cheers Jes