Took yesterday and most of today off for some family visitors and some personal stuff. I didn’t get started working on the van today until 3:30. But it was a cool and overcast day, so I didn’t want it to go to waste.
I started by cutting the hole in the butcher block counter for the drop in sink. I felt bad to have to cut into that nice butcher block, especially after I had spent so much time applying the finish to it. But, I also need a sink in the van. I measured the cut about six times to make sure that I got it right. I also looked closely at the method for attaching the sink to the counter and realized that I needed another 1/2″ on each side. That will force me to move one of the aluminum extrusions over one inch. But that will be done another day.
I considered a couple of different ways to cut out the hole for the sink. The hole is 14″ x 14″. I figured that I could either use my circular saw to do a plunge cut or drill holes in the corners and use a jigsaw to cut it out. I was concerned that the plunge cut with the circular saw may be hard to get and exact cut – too many variables. And I don’t think it is particularly safe. I was concerned about using the jigsaw, because the butcher block is 1 1/2″ thick, which is right at the limit of my longest jigsaw blades. I decided that I would start by trying the jigsaw. It was slow going, and it took a while to find the best blade for the job. But, eventually, I figured out a decent approach. Here is what it looked like cut out.
It’s a big hole. I test fit the sink next, and the good news is that the sink fit.
The bad news is there wasn’t enough room between the sink and the butcher block for the mounting hardware. So, I used the router to cut a 1/4″ groove in four places to make room for the attachment hardware. I sanded down everything and vacuumed up the sawdust. Then I applied the first coat of finishing oil to the newly exposed wood. I need to wait at least six hours for the second and final coat of finishing oil, so that means it will likely be done tomorrow morning.
Then I moved back into the van and worked to finish the electrical work. Two days ago, I ran the wires for the galley. Today, I installed the outlet for the microwave, which will go into a cabinet near the ceiling above the galley. I also wired up the circuit for the under cabinet LED light. Here is a picture of the additional wiring work.
Next, I fabricated the wall panel that will go behind the microwave cabinet. I had made a mistake when I made it the first time and had to re-make it. I cut it out of 1/4″ birch plywood, as the other ones are. Then I cut out a hole for the 120V outlet. I applied Landau foam to the back of the panel, but I didn’t apply the Minwax paste to it, yet. When I’m gloved up to do the 2nd coat of finishing oil for the butcher block, I’ll apply the Minwax paste to this last wall board.
That was it for the day. I spent about three hours. I just keep plugging away.