Day #81 Van Build – 9/17/25

Every day, I’m only able to work on the stuff that I have parts for. Reminds me of when I was a manufacturing manager. I have lots of stuff on order, but just waiting for it to be delivered.

This morning, I made a wall panel for the end of the electrical cabinet nearest the lower bunk. It was an easy task, but that is where I was at with parts. Then I started working on the measurements and plan for the shelving that will go above the electronics cabinet. I used my digital level to determine the length of the key outside aluminum extrusion rails. At mid-morning, I had some errands to run. So, I took a break until after lunch.

USPS delivered the extension cord that I needed for the microwave. It has a very narrow plug, which allows me to push the microwave further back and have a smaller cabinet above the galley. Here is the difference between the two plugs.

I did some cable management in the microwave cabinet to make sure everything was neat.

Then I plugged in the microwave and inserted it along with the mounting hardware that came with the microwave. I powered on the outlet and the microwave worked. I’m glad to have received that extension cord so that I could complete that task. Here is what it looks like.

One of the errands I ran at lunch was to pick up some plumbing parts to finish the sink install. So, I connected everything with the parts that I have. It’s not yet the way I want it, but it will work. I’m still looking for a quick disconnect fitting for the fresh water tank.

I got some help from Elizabeth to finish the work on the folding table. I needed to trim 3/4″ from the width of the table so that the eye bolt that I will attach to the table will clear the sliding door of the van. Elizabeth held the door while I used the jigsaw to trim the table board. Then she held the board again so that I could drill the hole for the eye bolt. After that, I used some wire cable to create a stop for the table at the level position. I used my digital level to ensure that the folding table was level and tightened the cable clamps at that length. It came out good. I still have to figure out a better way to hold the table upright when not in use (or travelling). I’ve been using a bungie cord, which works fine. But, I’m searching for a more elegant solution.

I had taken advantage of all the material that I had purchased or received in the last two days. So, I went back to working on the shelves above the electrical cabinet. I used the plan to create a cut list and cut out most of the lengths of aluminum extrusion. I drilled and tapped these pieces where necessary and put together the basic frame of the shelves. I connected them to the top of the electrical cabinet extrusion to determine where to put the anchor points on the unistrut in the ceiling. Then I took it down and drilled the holes for the unistrut. Here is what it looks like back up in the van.

It is very solid. I also made and assembled the aluminum extrusion for the shelf that will sit half way up this frame and bolt to the anchor points in the unistrut on the wall. However, I’m short some hardward to install it. I’ve got a ton of hardware on order and when It gets here I’ll mount that section.

I’ll continue to wait for more material to arrive, so I can continue the van build. Tomorrow, I’ll be able to work on cutting the wood for the two shelves, then we’ll see what happens next.

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