#2

[ghcoe]

So now the scarry part. I had to transfer the pattern to the inside so I could confirm the door placement and transfer the pattern to the inside. I drilled holes and pushed skewers through at the radius points.

Drill and Skewers

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Then I verified the transfer was correct by using the skewers as a guide on the door frame.

Correct?

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Then I used the frame to transfer the pattern to the inside.

Inside Pattern

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[ghcoe]

Then it was time to do the surgery. I used a piece of flashing for a straight edge and a box cutter to cut the canvas with on the outside and inside.

Cutting

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Then I peeled the canvas off the walls.

Peeling Canvas

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Then I cut the foam out with a jig saw. I cut back from the edge enough for me to use a hot wire for the final cut. I did this because often the blade on a jig saw will wander and I did not want to damage the canvas covering the inside.

Cut Foam

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[ghcoe]

Next it was time to use a hot wire to make the final cut.

Hot Wire Jig

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The hot wire makes nice clean cuts and does not harm the canvas.

Clean Cuts

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The compartment wall is going to actually intrude into the door opening about a quarter inch. I am using flashing to convert the door to a clamp ring type installation. There is a conflict at this location since I didn't want the flashing on the inside where the wall was going to be. So, to overcome this I am creating a groove for the front camp ring to fit into.

Slotting Foam

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[ghcoe]

Now I had to cut the floor mats to accommodate the walls that are going to be installed.

Cut Floor Mats

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Then it was time to cut the walls.

Cutting Walls

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On the ends of the walls, I hotwired a dove tail groove. This will allow a place for the Great Stuff to expand into and create a stronger bond to the other walls.

Dove Tail

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[ghcoe]

Once the walls are in place, I drilled holes into the dovetail groove big enough to insert the Great Stuff tube into. Then I injected Great Stuff into the dovetail groove. At this point the Great Stuff has filled the dovetail and is oozing out of the holes and imperfections in the wall joints.

Walls installed

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Once the Great Stuff cures I clean up the areas it oozed out off and then I apply Dap caulking to all the edges.

Caulk

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You can see now how the front wall intrudes into the compartment a bit.

Intrusion

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[ghcoe]

So now it is time to install the door. I use flashing on the inside and then clamp the door (after installing the butyl sealant) and the flashing together, sandwiching the foam in-between. Then I install Truss Screws through the door frame (through holes I predrilled) into the flashing.

Installing Clamp Ring

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This is what it looks like once installed on the inside.

Clamp Ring Installed

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[ghcoe]

Now I moved inside again to install the shelves.

First, I cut some shelves to fit.

Shelves to fit

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Next it was time to cut grooves into the walls and the end of the shelves where they come together with the walls.

Hotwire Grooves

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Here you can see the process. Back wall is the layout. Right wall is the groove cutout. Left wall has the foam jointer mocked in place. The jointer will be glued into the groove in the wall and in the shelf once everything is installed.

Groovy

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[ghcoe]

Here you can see the jointers installed in the walls and the shelf sliding into them.

Sliding In

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Here you can see the shelves test fitted.

Shelves Slid In

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When the shelves were test fitted I marked the front, top and bottom edge of the shelf at the front edge. I then used a box cutter to cut at these marks once the shelves were removed.

Cutting for supports

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[ghcoe]

Then I use a soldering Gun to cut grooves into the wall where I cut earlier.

Hot Cut

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Then I use a little piece of flashing to test fit before gluing in the shelves.

Test Fit

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Satisfied, I glue in the Shelves and install the front shelf supports

Shelf Support Install

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[ghcoe]

The flashing goes into the wall about 1" one each side. This adds extra strength to the shelf edge. Once I got the bottom piece in, I installed another piece of flashing on top.

Two Flashing

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Once the flashing is in place, I use some clamps to squeeze the flashing together. I use a piece of wood on the bottom and top to spread the squeezing force across the whole shelf. I also place a piece of 1x4 across the front for a shelf edge. I drill through the 1x4 but not the flashing. then I use a Truss Screw and screw it into the flashing. This holds the shelf edge in place as well as screw the flashing together to keep the flashing tightly clamped on the foam.

Shelf Face

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A picture of the shelves installed.

Complete

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Not shown is that everywhere there is bare foam I installed black indoor/outdoor carpeting. Looks nice and is easier to install than PMF at this point.

[ghcoe]

More information on the outside door and compartment to come.

[featherliteCT1]

Those shelves look great!

[ghcoe]

Those shelves look great!

Thanks! I thought they turned out pretty good. I was pleased with how things all slid together.

[ghcoe]

So, in the back compartment I needed to make a couple of shelves. One shelf would just slide in to hold my Coleman stove, the other for my 12V refrigerator.

I made a light frame at the back of the compartment. This spaced out the distance so my drawer slides I got would clear the door frame. I used flashing for the shelf slide supports.

Light Frame

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On the front wall I channeled the foam with a soldering gun similar to how I did the channel in the door frame. This is where the flashing will be glued into the wall. I had to use a small spacer behind the channel so the shelf sliders would clear the door frame.

Front Channel

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Then I installed the shelf sliders.

Shelf Sliders

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[ghcoe]

The top shelf is for the 12V refrigerator the bottom one is for the Colman stove. The top shelf has the roller shelf sliders so the cooler can be moved in and out of the doorway. The bottom shelf is actually just designed to slide onto the rails I made with flashing. This is so I can take the whole shelf out with the stove since the stove is only in there for transport.

Shelves

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I installed some locks on the shelves so they wouldn't slide back and forth in transit.

Locks

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Then it was a test fit before adding indoor outdoor carpeting.

Cooler and Stove

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