Date:         Fri, 20 Jan 2006 22:09:03 +0000
Reply-To:     Dave Vickery <davevickery@HOTMAIL.COM>
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Dave Vickery <davevickery@HOTMAIL.COM>
Subject:      Re: how was this poptop added?
Comments: To: drillock@EARTHLINK.NET
In-Reply-To:  <43D14E97.2090705@earthlink.net>
Content-Type: text/plain; format=flowed

I used 1/2" cabinet grade plywood.  It just rests on the ribs at the high
point and I used angle cut 2x4s to rest on at the edges.  It is one piece of
plywood from the canvas at the rear to where the opening starts.

Without any recesses cut into the plywood, I had enough room for the front
board to fold over onto the rear stock cushion (so 1/2" plywood, 1 3/4"
stock mattress, and stock front board without mattress fit fine).  But that
didn't leave enough room to store the front cushion up there too.  By
allowing the stock front bunk board to fold over on itself it doesn't take
any room over the rear mattress.  Then by reducing the mattress thickness I
can fit both mattresses up there with the top closed.  When I open the
poptop, I just fold the doubled-up front board up over the rear mattress and
out of the way.



>From: mark drillock <drillock@EARTHLINK.NET>
>Reply-To: mark drillock <drillock@EARTHLINK.NET>
>To: vanagon@GERRY.VANAGON.COM
>Subject: Re: how was this poptop added?
>Date: Fri, 20 Jan 2006 12:56:55 -0800
>
>Dave, what did you use for the plywood in the rear part? Is it a single
>large piece resting on top of  the raised roof ribs? I have been
>thinking about using a router on the board to make recesses on the
>bottom side where it hits the ribs so the board will sit lower down on
>the roof. This might let the full front board fold over it instead of
>cutting and hinging the front board like you did.
>
>Mark
>
>Dave Vickery wrote:
>
>>Mark's the man,
>>
>>But I managed to get the full bunk up there using Mark's small hole
>>approach.  I had to make some compromises, like switching out the 1 3/4"
>>foam for 1" foam.  And I cut the front peice of plywood in two and put
>>in a
>>hinge so it folds over on itself and doens't have to be folded over
>>the rear
>>mattress when the top is down.  That way both mattresses fit up top
>>(although the front mattress is stored loose over the rear and pulled
>>forward when needed).  1" foam doesn't sound like much, but it seems
>>to feel
>>the same as the stock cushions.