Here is a closeup of the upholstery fabric we picked out. The basic color is a light tan, but it has other colors woven in that move the color towards a reddish color that really matched up to the flooring and the Luan.
Today, I started out by stretching the fabric and two layers of batting around the luan boards. I stapled the fabric with about a thousand staples for all the upper trim that covers the area between the walls and the ceiling. Then, I did a few experiments trying to find the best way to attach the boards after they were upholstered.
I had hoped to use wood screws with little hinged caps. I found the screws would twist up the fabric and batting into a wad, and eventually tear the fabric and make it unusable. Then, I tried adding a drop of hot glue on the fabric and that was barely better than without the glue. I tried glueing the hinged screw cover to the fabric, and it worked no better than with the hot glue. Finally, I tried using 1 1/4 inch brads in my little air nailer, and it worked acceptably. Also, it made it quick and easy to install the boards without an assistant.
Now that I had a workable method of attaching the upholstery to the walls and ceiling, I tackled the "headache board" I planned to install above the back door. It is a piece of Luan that I cut to fit the space just above the back door frame. I glued a 1 1/2 inch piece of memory foam to the Luan with 3M 77 adhesive spray. Then, after stretching the fabric over the foam and stapling it to the board, I faced another mounting problem. Again, I couldn't use the screws I had planned on, because they would ruin the fabric. I couldn't use the brad nailer, because I was going into a piece of stainless steel. I decided to use self adhesive industrial strength velcro. After putting about 2 feet of 2" wide velcro cut into 5 strips on the back of the board, I peeled the other side's backing off, and stuck the piece on. It is solid enough that I don't think I'll be removing it unless I plan to replace it, because the Luan may crack before the velcro or the adhesive let go.
So, here is a picture of the upholstery on the bed/sofa, trim boards with accents, and the foam padded board mounted in the back of the trailer.
We stayed with the same theme for the trim boards in the front.
The walls along the side are a little higher than the ones in the nose cone, so I had to deal with the transition of the rear trim boards to the ones in the nose cone. I cut a wedge shaped piece and covered it with the cushion fabric, and I nailed it to the back piece, front piece, wall, and ceiling.
And this picture shows the LED Dome Light and the two LED reading lights turned on.
Here is a picture of the v front counter with the original incandescent dome light above it turned on.
In the sofa position, the seat is the front cushion, with the back being the second cushion, and the third cushion stows neatly behind the seat back. Here is a picture taken from behind the trailer with the doors open to show where the third cushion stows when in the sofa position, and also the storage under the sofa.
Here is a pic of the bed in the bed position from the front area.
The cushions are a composite of 3 inches of poly foam with 3 inches of memory foam on top. We elected to not use piping, because it just makes more bumpy things under you. After sitting and laying on it for a bit, it feels pretty comfy. I'll be anxious to see how good it is for a night of sleeping. Here is a pic of the bed taken from behind the trailer with the doors open.
While I was at my sister's home in Salt Lake, her son looked at the trailer and asked me if I wanted to put bigger tires on the trailer. I told him it was in the plan, but I hadn't got there yet. He made me a great deal on a couple of slightly used BFG All Terrains that were 31x10.50x15. That works out great for me, because they are about 5 inches taller than the original 205/75/15 tires and they fit under the stock fenders with the 4 inches of lift I already had installed. Also, they work on the stock wheels, so I didn't have to get a new set of wheels. He even mounted them up for me. Here is a pic of them on the trailer.
This just about completes phase one of the build. The trailer is now camp ready. I have a vent cover and a porthole to install, and then we go into the testing to see how it holds up on the "corrugated" dirt roads around here.
I'll add more pics when I get it loaded up and take it out for the test camp.
Stay tuned!
Gil
That would be the most burley off-road trailer ever! 