Wall Panel Start
-I then started on the window boxes starting with the driver side. I used ½ Baltic birch to build a frame which was scribed to the van body. After getting the back scribed I used a small cut off of Ό Baltic birch which I will be using for the wall panels to find the wall curve. After getting the window boxes roughed out I pulled them out and glue and screwed them together trimming up any remaining parts.
-I then went to the passenger side and repeated the process. The one difference on this side is I had to create more of a curve horizontally as I am trying to curve the wall panel in both directions so it planes in nicely with the 60/40 door pillar which sticks out further than the rest of the wall.
-After getting the window boxes done I started on templating for wall panels. Starting with the driver side I cut and scribed multiple pieces of cardboard together to get a rough template. After getting the rough template together I traced that template to a clean full length cardboard piece since I was worried the pieced together template wouldn't get me accurate enough cut lines.
-After the template was done I cut out my wall panel. I am using Ό Baltic birch which proved to be a little problematic. As you can see the wall panel did not want to conform to the van body.
- I then pulled the panel back out and did some shallow kerf cuts in both directions to the entire backside of the panel. This helped a lot! I drilled out holes and used standard screws as temporary holders until I can install the Ό x20 threaded inserts. I am using some aluminum finish washers and black coated stainless steel Όx20 bolts to attach all the panels.
-After getting panel #1 on the driver side in I repeated the process on the passenger side. Like mentioned before I curved the panel and ran it all the way to the door seal which should allow me to tuck the fabric into the door seal once I do the upholstery. There is also a bump out that pretty much runs flush with the wall panel (the black section in the picture) which I plan on running the foam and fabric straight over to give a smooth panel look. EDIT: I found a picture and added it in. I also will add a small return piece to close up the gap on the bottom side near the door.
-I then went back over to the driver side for panel #2. I left a ⅛ gap between the two panels to allow for the fabric to roll around the edge and create a smooth transition. I also had to add some additional blocking to ensure that the curves of each panel would line up together. Pictures looks like the joint line is crooked, but I promise it's all straight.
-I then went to the ceiling. For the ceiling I am using the same material and bolts. So I started with the nutsert process. There is a centerline slot on each cross member that I enlarged to insert the nutsert in and worked my way back. I then drilled the matching holes in the 4x8 Ό Baltic birch and mounted it up in the van. This way nice not to have any scribing to do!
-Next up was the small section of roof in the rear that the 8 sheet couldn't reach. I am going to try to join the two ceiling panels as one using some connection blocks and then upholstery it as one so there is no seam. The connection worked well as I used inserts in the blocks and bolts through the panels which will get buried under foam and fabric.. at least that's the plan for now.
-Next thing I did was drill out all the holes of where I am going to add bolts and inserts. Most will be into the wood substructure, but a few will be into the van metal which will require a nutsert. Probably have more attachment than needed, but I don't want any squeaks, so I figured more might help with that. (No pictures)
-I mocked up a few ideas for the transition pieces between wall and ceiling. I will be using this as a wire chase as well as a switch and controller mounting area so I am leaning toward the more complicated angled box structure, but I am still mulling it around. Does anyone have any suggestions or ideas?
Option #1 & Option #2
-Hopefully soon I will be ready to cut out the windows and start pulling things apart to do the wiring, insulation and then upholstery!