This video shows how we built and finished our cabinets, built on extruded aluminum
We didn't have much room to spare, so every inch was put to use.
Even the back had two extra seats, for travel and to kick back and enjoy the views.
To match the curved van walls, we used cardboard to make precise stencils.
It was a 4 day process, but made sure we didn't waste any material and had a professional finish
After cutting the cardboard to the approx size, I trimmed it little by little until it fit perfectly
Once it was an exact fit, I used the stencil, to trace onto the birch plywood.
It's important to take your time on this step to shorten the time fitting the wood piece.
Cardboard is cheap, so don't be afraid to use your stencil to make an even more accurate stencil.
Fit, trim, and fit again. Curves make this an especially time consuming process.
Once cut, use a coarse grit sandpaper with an orbital sander to slowly remove material.
And before anchoring your work, check level and square to save time on your next steps.
Once clamped in place, I used 1/2" corner brackets and small wood screws to attach the 1/2" plywood.
The cabinet face was cut from a single 5/8" sheet of birch ply, so the grain would carry across doors.
Everything else was made from 1/2" and 1/4" plywood to save weight.
The rear cabinet had three sections. The center cabinet was large enough to hold clothing.
Corner brackets were used liberally as they are cheap and easy to install.
This it the center cabinet, the aluminum pillar holds the doors and allows clothing to be hung.
Always measure to ensure level and square, it will make lining up the doors much easier.
We wanted a lighter interior, so we used a white stain to finish the birch plywood.
It was easy, but time consuming to apply. The birch only needed one coat.
Applied with a cloth, the stain is wiped on and wiped off, never being left dripping wet.
If you wanted a more opaque finish, a second coat could be applied.
Once finished, allow adequate time for the stain to dry before applying a protective finish.
We used Varathane Diamond Wood Finish, as it provides a hard, clear, protective coating.
They recommend 3 coats, as the plywood absorbs most of the first and second coat.
This product also "wets out" very well, leaving a smooth finish, devoid of brush stroke marks.
You'll want to use a fine grit sandpaper between coats to get a glass-like finish.
We chose to go with a satin finish to help reduce glare and let the wood grain pop.
Second and third coats can be applied 20 to 30 minutes after the previous coat.
Drips will create more work once dry, so be sure to blend them in.
Be thorough and paint from one side of the work to the other.
It's also wise to paint concealed areas before assembling the cabinets.
Use light reflections to make sure you covered the entire surface.
We missed one small spot on a cabinet door and have to sand and add a coat to fix it.
These cabinets used soft close hinges, and need to be fine tuned once installed.
They also have quick-release mechanisms that make it easy to pop a door off when needed.
Fine tuning can take time, but makes your cabinets look amazing when finally done.
We also installed the switch panel, which had handy DC circuit breakers built right in.