The Bed

Like all loves in life there are some parts of motorhoming that I love more than others. The thing that I love the least is 'making the bed'. I mean this in the sense of not just changing the sheets but in the sense that in many internal configurations there is a need to build the bed from boards and cushions before it can then be 'made' with sheets and quilt before, finally, one can slip into it. 

The bed made from boards and cushions is not a real bed, it has to perform as seating during the day so the cushions are not like a real mattress. So, there is compromise on both fronts. 

There are various ways around this problem. A fixed bed, which would have made the camper too big or, the pull down bed which stows away in the ceiling during the day and is pulled down at night.

I decided on a modified 'pull down' approach. The original plan was to make a bed frame and base which I could raise and lower into the ceiling using a suitable lifting system. Whilst searching for bed slats on the IKEA website I found a (cheap) ready made bed frame. The combined weight of these and the mattress came in at about 35 kgs. 



I then needed a lifting mechanism. To cut a long story of sleepless nights and internet searching short I discovered a Thule roof box storage lift. This is intended to fit to the ceiling of a garage to enable a roofbox to be lifted off the roofrack and stored in the ceiling above the car. Weight limit 100kgs. I did not want to have all of the lifting mechanism on show in the ceiling above the bed but felt that I could modify things and have the mechanics under the base of the bed. This would also make the winding mechanism more accessible (and possibly allow operation with a cordless drill?)

Combined cost of this, bed, slats, mattress, lift was about 280 pounds. Good value and this would be a 'real' bed. 

The bed frame was a tight fit in length but, in theory, would fit. However, the internal fittings on the wndows (cassette for blind and flyscreen) invade the space so I had to shorten the frame. I also had to reduce the height of the headboard and cut off the legs. 

The THULE Multilift envisages the winding mechanism being attached to the ceiling.

I inverted the idea and attached the winder to the underside of the bed. 

Guides were fabricated to carry the lifting cord around the ends of the bed.

Bed in (sleeping) position

Having fitted pulleys and cord (see next post for details) I had my first go at winding.

Further work on window installation 

I have installed a trim above the window to protect the top seal from water flowing down the walls and for a bit of decorative effect. These are of plywood cut in sections on the CNC machine. 

Rear window

Internal shot showing cassette blind and flyscreen part

First Window Trial

The edges of the vinyl roof were trimmed back and a cover of angled checkerplate installed at the edges for protection.




The first window opening cut back to the internal frame with the trim router. 

...and the window slotted into place.

Roof Cover

I had a piece of vinyl sheeting from an earlier project and used this to cover the roof.



Frames had been installed on the underside to suit the roof lights and these were first opened up with the trim router.

Then the vinyl was secured using strips of contact adhesive at 300mm centres. 

Back in the UK

Once back home the unit was demounted ready for further work.....

More wall construction and the floor

Once all sections of the wall were complete the skins were trimmed back to the size of the original frames with a trim router. 

..and fitted back into the metal framework.

The external ply was left uncut with the exception of the rear window and door. These cutouts will be made once fully ready to fit the windows. The wooden frames provide a guide for the trim router and the internal wall panels were trimmed back to the frames. 

Floor construction method was similar but this had to be built in situ. Underside of the lower floor panels was varnised before fitting. 

It is worth noting for historical context that at this stage of the project the coronavirus outbreak was starting to take hold. We decided to move ourselves and the project bac to the UK since it was uncertain how long this problem would last. 

There are not many photos of the next few days of work. Time was a bit pressing.

The roof was installed. 6mm marine ply screwed directly to the metal frame and sealed all round with Sikaflex. Wall panels were sealed and screwed in place. 

We then loaded it up. 

... and set out for home.

Wall panel construction

A bit of a catch up.........

We moved the project to a warmer and drier part of the world to continue the work.

The frame was deomounted and painted with hammerite.

The side walls are to be comprised of 3 panel sections, laminated with a 40mm PIR insulation core, internal wall of 4mm ply, external wall of 6 mm marine ply. 

Methodology.

Construct a light wooden frame within the metal frame. 

Use this frame to size and mark the insulation material. 

Cut the insulation to size and fit inside the wooden framework. Glue with expanding foam glue. 

Once the glue has cured mark and cutout frames for windows and hatches 

Glue the frames in position

This creates the 3 wall sections which can now be removed to apply the internal and external skins. 

Glue is applied. The skin ply place in position and the section placed in the improvised press while the glue cures. 

Turn over and apply the other skin using the same methodology. Shallow holes were made in the insluation board to provide a key for the expanding foam glue.