Materials

• 80/20 15 series 6ft sections
• 80/20 15 series 8ft sections
• 80/20 15 series angle brackes
• 80/20 15 series nuts
• 80/20 15 series bolts
• birch butcher block
• sink
• induction stove
• 1/2in plywood
• isotherm 130 elegance fridge
• Threaded inserts
• silicone
• angle brackets

Tools

• scribe tool

‍

Process

I started the cabinetry by building a frame to hold my fridge. This would determine how wide the cabinets on the left side of the van could be.

You can see the fridge cabinet mounted. I put a sheet of reflectix on the side facing the heater. This side will be a part of the heated closet, and I wanted to minimize how much heat the fridge sees from this proximity.

I then built the overhead cabinets. I had to cut the horizontal sections perpendicular to the wall at an angle in order to actually have a cabinet that meets at 90deg.

Then I built the whole galley unit! This whole construction took less than 3 hours and completely transformed the space.

I then started to make a template for the countertop, marking holes for where the sink and stove will go.

Here's what an unfinished piece of 8ft birch butcher block looks like!

I used the template to trace the holes onto the birch block.

I put painters tape around the edges where I was to cut to try and minimize the amount of wood chipping.

Cutting this was significantly more difficult than any other wood I had cut for the van so far. I had to get different blades, and go really slow. A little later I learned I had been using the jigsaw wrong for AN ENTIRE YEAR. The base was always wobbly and I did not know it was possible to lock it down... in hindsight I can see how that is stupid, but at the same time I'm kind of impressed with how far I made it using it in a significantly more difficult manner.

This is what the block looks like fully cut. I then sanded it down.

And used mineral oil to seal it. I kept it wet for about 30min and then allowed it to dry overnight. I did both sides.

This is what the sealed vs unfinished birch looks like.

I fitted the butcher block to the counter and marked where I'd need to drill holes to fit my brackets. I then removed the block, drilled holes, and screwed in threaded inserts. Then, I put the butcher block back on and I was able to use 5/16 screws to get it secure.

Then, we installed the sink and stove. These required a bit of creativity since it was a tight fit between the aluminum for the sink, and we had to invent a way to secure the stove down. We ended up using 90deg brackets that we screwed into the wood, and self-tapped into the thin sheet metal of the bottom of the stove.

It was then time to (re-)build my bed platform. I constructed upwards from the water tank cage and made a platform that was level with the electrical assembly. The goal in this construction was to keep a slot through which I could put my skiis.

Then I installed the extension of the butcher block, and started to fit pieces of plywood to the galley unit.

Next was building the heated closet. This one took a bit of reworking before I finally got it right.

Started adding plywood around the upper cabinets too, made a large seat out of 80/20, and covered that in plywood too.

Making templates for anything going against the van walls was by far the hardest thing. I started with paper, then did thin plywood, then thin plywood + paper, and then finally the real thing.

Really starting to look like a home now!

Same thing, from the other side.

Seeing it like this is inspiring to keep going.

Then I painted everything! Finally painted the bed panels as well.

Started making additinoal templates. I think this piece of plywood was my best one by far.

With all the white it looks even better!

Then I started making the enclosure for the shower pan -- my first true woodworking project in the van to date! I pade pocket holes on one side of each piece of plywood, and added wood glue to secure things extra well.

It will also house the composting toilet, so I cut out a lip to make it easier to sit on.

I still have need to put red guard and FRP board on it and paint it and reinforce it additionally but I will update as I get there!