After a lost day yesterday, I was able to put over six hours of work into the van today. I started by attaching the completed window frame, and I think it looked good.
Then I spent the rest of the day working on the wall panels. When I went to the lumber yard a couple of days ago, I picked up eight 1/4″ birch plywood sheets (4′ x 8′ sheets). They were sitting in the back of the van, so with my work table now clear of the window frame, I started laying out the wall panel sheets and cutting them to size. I tackled the hardest ones first, which were the one around the window frame, the one around the slider door on the passenger’s side (had to create a template for around the styrofoam “blob” in front), and the one above the window frame on the driver’s side (same type of styrofoam “blob” that needed a template). Those three took me until lunchtime to complete, but I thought they looked good. I used the Ram Board that I had to create the template for the curves on these three panels, then transfered those curves onto the plywood. I then used a jigsaw to cut them out. Sometimes, I had to trim the panel another time to get it to fit correctly, so I was in and out of the van a lot.
Then I spent an hour and a half after lunch and completed six more wall panels. These were faster, because they were not very complicated shapes. So, overall I cut out nine of 16 wall panel sections. I made a lot of sawdust today. I probably have another two hours of work to cut out the rest of them.
Each wall panel requires several more steps before it is ready to install. I may need to cut additional holes for electrical outlets and switches, I will prep the surface with two coats of Minwax, and I will glue landau foam to the back of the panel. All electrical wires need to be routed before securing the wall panel as well. So, it will be a while before any are ready to put up.
I’m out of town for the next week, so it will be a while before I’ll be working on the van again. I do have several items on order, so there will be lots to do when I return. Mostly, I plan to focus on running the wires in the van and installing some of the outlets and switches so I can attach some of the wall panels.