PermaLink Caravan wall, floor repairs and sofa bed.10/09/2009 11:06 AM


Repairing the walls, replacing the lino and installing a sofa bed.

See the Pictures Here

The latest installment of caravan works, with a couple more things completed and a couple more projects still left to do before we head off to Marlo after Xmas.

Although, the
bumper we made back in March this year was a success the bike mounting was a bit of a disaster. The issue is that the suspension on the caravan is taken from the days of horse and carts, with dual live axles connected via leaf springs and no dampers. This might be fine for something travelling at 15km/h but travelling at 110km/h it does tend to lead to everything being shaken to pieces.

The bike rack with the bikes on it bounced its way down the highway and gained enough momentum to flex the bike rack and the bumper as well which lead it to keep bashing into the rear of the van. The rear of the van isn’t very solid and this constant pounding caused flexing in the rear wall which in turn caused the
repairs that I did inside in 2007 to crack.

So my solution has been to place a piece of 50mm angle iron across the rear of the caravan to not only strengthen it, but to give a fixing point for the top of the bike rack and to cover the dent that was caused. Although this is a less than attractive repair especially considering its painted black, I hope that it provides a solid enough solution.

To repair the inside wall I cut back the damage and bogged it back up with car filler, when choosing the car filler I noticed one that was supposedly “flexible” what I soon learnt was this actually meant “it never actually dries properly so is a damn bugger to sand without the sand paper clogging!”

I removed the cushioned bed head, moved the bedside light over as far as i could and painted this wall. I also repaired the damage on the side wall caused by storing things under the bed and painted this too, because we also had big plans for the bed.

Our intention has been to do something with the bed from the very first time we used the van back in 2007, but the dilemma has always been what to do. Caravan beds are an odd size, slightly smaller than a double bed and due to the small market they are also very expensive.

We have always wanted to put a sofa bed into the caravan as it seems silly to fill 1/3 of the van with a bed that isn’t being used during the day. But this in itself was a problem, most sofa beds are uncomfortable, dimensions needed to be exact to fit and finally we needed to be able to get it inside via the narrow 600mm door.
This is where IKEA came to the rescue they have a Sofa bed that just fitted and came in flat pack so could be assembled one inside. The tolerances were so close with things like the internal wheel arch that we were still not sure if would fit without modification until it was in place, assembled and folded out.

One issue that has been on going for a while now has been the small triangular piece of carpet up near the front seats of the caravan; it gets/is putrid and impossible to clean.
The only option was to pull this piece of carpet up and replace the flooring but I couldn’t figure out what to use on the floor. I thought about lino but it is very expensive, there is huge amount of waste and would involve a massive amount of cutting. (the original lino was put down before any cupboards etc are built into the van).
Another option was the laminate timber look flooring, this was cheaper than lino and had far less wastage but it lifted the floor level up 5mm plus and would require timber quad to be cut right around the edge to hold it in place.
Whilst over a Peter and Anna’s the other weekend Peter mentioned self adhesive lino tiles and straight away I new we had a solution to our flooring needs. After a few samples we finally settled on an imitation cork tile, it is the right color and fits into the “era” of the van.
It took less than 3 hours to do the floors in the van once the old lino was cut out and removed; it had almost zero wastage and cost only $60 to do.

Next on the agenda is to make a bunk bed and to make a hinged swing out coffee table for our new sofa bed lounge room.

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