In this post I will show how I make a cabinet door from a big sheet of plywood. After lots of measures it’s time to cut these numbers out to actually real things, this time cabinet doors for a overhead locker/storage to the Highroof Bay.

Draw up the dimensions on a 12mm lightweight plywood (never use ink pen!). Then cut it out with a steady hand and a jigsaw. Cut out laminate in slightly bigger size than the plywood, add 3M laminate glue on both sides, let it dry separate for 60mins. Then press the laminate together with the plywood and put it under pressure for at least 1hour or 2. Repeat it again to do the other side if needed. After this it’s time to use the electric wood router and cut out the coutures. Then cut a profile in the end of the door using a special router bit. When this is done you can start knocking on the edging, you can buy these from special wood company’s or camper conversion firms. Then measure out were you want the doorknob, drill it out, press in a bezel and install the lock. Mount hinges. Now you have one complete door, just everything else left to do 😉 Good luck!

Some of you have been asking for build plans for the Highroof Bay bus interior, but the only plans I have is in my head, sorry guys! 🙂

Have now started with the interior on the Highroof bus. Have put sounddeadning mats in floors and doors, sprayed it all with wax for rust protection. Then added insulation (Refectix) a material of aluminium with plasticcells of air in middle. NASA came up with this tecnology when insulating spaceships actually! After this I put some extra 5mm insulation foamboards (green) then 15mm marine plywood and then a new linoleum carpet in Classic checker pattern, went with light grey to match the grey details on furnitures. The furnitures itselfs is in Light Oak wood finish (laminate). I built it all in a special  extra light plywood 15mm. This interior is gona weight nothing!! And thats great in a slow VW bus, all the stuff thats going to be loaded in the cabinets are heavy enought 😉 The kitchen pod/cabinet is featuring a new Vitifrigio fridge on 48 liters + 2 liter freezer. A new small owen in stainless that will be running on 240v (euro). The zink is from a newer crashed/parted out Knaus campervan I bought cheap online. The lid in top is hiding a gastove and the cupboard in bottom will be housing the greywater tank etc.

Still have plenty to do before I can start restoring the 1800cc AP engine.

More to come soon!
#highroofbayproject