The Banquette: Coming along nicely

When last we visited the Great Banquette Conversion of 2009 Chris was making himself stupid by curve-fitting with a belt sander.  Mercifully for  all concerned, he went back to the tried and true Compass Method that we used so successfully before.  We completed both seats and the table top then added some Ikea drawers, which are going to work just fine. There is quite a bit of clearance at the back of an Ikea cabinet, even though we cut away part to fit, the drawers fit perfectly.

Dry fitting the BanquetteI spent some time figuring out the best way to support the table so it can be both a table and a bed/lounge.  We used a laptop stand as a prototype to figure out how high the table should be. Usually, we like to use Marine components because they are just better quality. But in this case there was just not anything that looked right. Most involved having some part of the table leg protruding below the ‘deck’. Hmmm. Not so much of a good thing with a trailer. So I was back looking at trailer parts.

I wandered over to Vintage Trailer Supply and found a nice support system that works for the table level and sleep/lounge level.  We bought two Table Wall Mounts (one for the table height and one for  the bed/lounge height).  They are quite reasonably priced and have worked out well.

Vika-JB Weld Table Leg Mod

We added a 30″ Vika table leg from Ikea which we can remove when the table is lowered.  We used JB weld, an old family favorite, to attach the Vika base to a bolt that fit a groovy orange knob we had laying around, and then we screwed the base into the bottom of the table. When the table is  used as a bed or lounge the base and knob are hidden under the leg, but when the table is used as, well, a table the groovy orange knob adds a bit of spice to the birch.

We are very happy with the finished effect.  The Ikea drawers fit perfectly and leave a bit open at top for handholds, recall that the base cabinets are actually refrigerator wall cabinets mounted on 1/2″ furring strips. Next to Chris, below, is the aluminum seat-level wall-mount.  We also added 1″ strips of aluminim for the table to rest on when it is in lounge mode.  Did we get the aluminum from McMaster-Carr?  But, of course! Well, it might have been OSH, too.

The Banquette..all done except the cushions.

We added Ikea birch drawer fronts to the Ikea drawers, they were a bit pricey but look so nice. We left the spaces between the cabinets and the trailer walls uncovered. We plan to use them as cubbies for laptop cases and well, more laptop cases. Our trailer bristles with multiple laptops on all camping trips – don’t ask – and we never have anywhere to put them.

We’ll probably cover the exposed side of the cabinet with purple or green plastic but are just not sure yet.  The white looks pretty nice; this may be a call we make when the upholstery is done.

We celebrated the finish of the woodwork with martinis in the trailer. That’s Chris there next to my fancy new power drill, it has an LED.  That reminds me that Chris needs to keep on his Martini Series he promised last year!

Next time, the foam!

McMaster-Carr…Heaven for the do-it-your-selfer

Chris and I moan on a near weekendly basis about the dire state of the big-box hardware stores.  If I go to Home Depot or Lowes or OSH for 9 items I come home with 5, 4 are of crappy quality and 3 actually work at all.  It’s pathetic. As recently as 10 years ago I could find just about anything close by. Not anymore.  If you are lucky enough to have a boutique plumbing store or small town hardware store nearby you are truly blessed, indeed.  If not, and you still want to tackle that Airstream restoration, home repair or trans-continental pipeline project then McMaster-Carr is the one stop shop for all your needs.

Pick a random page from McMaster-Carr, how about Fastening and Joining for example.

Heaven for the do-it-yourselfer

Heaven for the do-it-yourselfer

Its the kind of place where you can buy extruded sheet aluminim (you can choose the thickness and strength) to pre-hung doors and heavy industry rated exhaust equipment. We shop there for very reasonably priced stainless steel screws, bolts, and other hardware. Spend some time perusing.  I find the fasteners and joiners to be particularly compelling.  Where else can you find Metalized-Fabric EMI-Shielding Tape that is suitable for constuction of satellites, electronic vehicles, and robotics right next to galvanized wood screws.

You gotta love it.

The Banquette

So this trailer mod started like this:

Leslie: Set the table, it’s almost time to eat.

Chris: What table? (Looks around as if table will erupt from gaucho/couch like Athena from Zeus’s head.)

Leslie: Ah, yes. Hmm.

This is the OmniGraffle plan for the Banquette.

This is the OmniGraffle plan for the Banquette.

I’m not saying that having the trailer that with two couches, and thus was dubbed the “party trailer” wasn’t fun.  And yes, that is the adult party trailer, hehe. But the morning after those great parties would be so much nicer if there was  table to sit at. Anyway, for several years I thought about my very meager carpentry skills and the beautiful banquette plans that were clearly designed for people who were real carpenters, or who could at least nail two boards together without it looking like something that would shame a refugee shack.

Now my M.O., when faced with something that I might want to build, but that would take more carpentry skills than I have, is to make some measurements, transfer those to an OmniGraffle (or Visio for you WinDoze folks) diagram of my trailer, pour a glass of nicely chilled Chardonnay and pop the Ikea catalog.  Nine times out of ten I score, and for that tenth time, if I just wait a couple of years they will come out with something new and I will score again.  Yay me!

So for this plan we used refrigerator cabinets. Two of them.  We nearly completed a re-do of our trailer last year. We finished enough to use the trailer, and have taken several trips since then.  The Ikea cabinets are holding up very well and  we have been pleased with the results.  More on that soon. I really do need to finish those blog entries ; I like to see this as a journey.  Either that or I procrastinate very well.  But I digress.

The 36" Ikea over-refirgerator cabinet dry-fitted into the trailer.

The 36" Ikea over-refirgerator cabinet dry-fitted into the trailer.

This current mod allows us to seat 4 small people who are very good friends for dinner; it is snug. As an added bonus we get  some very nice storage underneath. Since this is based on Ikea cabinets, there are drawers that will fit.  This was important because the gauchos (couches) had 4 bins for underneath storage that we used.  We get a decent bed for 1 or 2 people and a great place to work and eat. You can tell from the drawing that we shaped the backs  of the cabinets to fit the trailer, but that was very simple; we just cut diagonal edges. We weren’t worried about how it looked because it will be topped with a sheet of very nice birch veneer plywood.

Here is the 36″ cabinet fitted.  It’s not attached to the floor yet. We raised the cabinet 1/2″ off the floor with recessed pine 2X4s. That gave a solid base and the recessed wood gives the cabinet a bit of a floating look. Very modern. Also, the drawers will not open if you put the cabinet directly on the floor, they need at least 1/2″ of clearance to open properly.

The green cabinet on the left is an 18″ Ikea base cabinet with 4 drawers; this was part of the previous Ikea mod.  We covered the sides of the cabinet with green plastic.  Makes for a fun and bright interior.  Bright colors are fun, but for the banquette we are going to stay with natural birch with a polyurethane finish. We plan to top the seats with bright orange upholstered cushions, but have not really planned that out yet.

or, My Friend the Belt-Sander.

A beautifully fitted curve or, My Friend the Belt-Sander.

Shaping the plywood seats is an exercise with our old friend the compass.

Or at least it should have been.  Chris decided to try to shape the seats using a belt sander after rough cutting the board.  Nearly 8 grueling hours later and the gods only know how many rounds of sand, fit, sand, repeat, he agreed that the compass is best.  However, the seats are beautifully fitted, aren’t they?

Chris had to go to Hong Kong for business, so we put the project on the back burner for a week. That was OK because I needed to figure out how to suspend the table.  I waffled between some very spiffy and pricy boat hardware from Garelick and  a home-grown method I cooked up with an Ikea leg and  aluminum channel.

Wonder which way I’ll go?

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