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Well just thought I'd start this thread now. I am only part way through the build as I don't get a great deal of time to mess around in garage lately.
When I bought my 2nd hand 90 Series RV, it had a damaged rear door trim. It had a small tear and the elastic to both pockets was shot. I'd rung around to source a replacement trim but the only wrecker I could find that had one was in Tassie of all places. I read many forums/posts that described and pictured tables being made to bolt to the existing trim that fold down ... I decided to go that step further and replace the rear trim as well as build the fold down table.
Now I know this has probably been done to death, however, I'm sure the server isn't struggling that much for space and maybe some of the minor things I do different to other my give some an idea or two for their own build up.
So far I have only finished the trim to replace the old one and am yet to build the table. I will update the thread (this first post) as I go with new images and notes.
Thanks to all for the inspiration and ideas ... so here goes!
I started off by removing the upper trim (below the window, above the door trim) which is clipped in by 4 or 5 clips along the front edge, I then simply pulled the trim off with a little muscle. There are plugs around the outside holding the trim on, my intention was to use these to fit the new trim ... but ... the 4.8mm masonite I was using was too think so I just pushed on to cross that problem later. I laid the old trim on the masonite and carefully traced out the outer edge, the door handle, washer refil access hole and holes for the grab handle. Next ... the power tools :twisted:
I used a jig saw and drill to cut out the trim, cutting ON the line so as not to leave the trim too big to fit the door. I used a electrice palm sander to clean up the edges and gave it all a wipe down to get ride of dust reading for glueing.
I used a marine grade carpet from Bunnings adhered with a high strength spray on adhesive from Clark Rubber. I trimmed the carpet at the edge of the holes for the door latch and refill access as once again, due to the thickness of the masonite and carpet, it would have been a problem getting things to fit with the extra layer of carpet had I folded it over the edges. For the outer edges I folded the carpet over and gave it a heavy dose of the adhesive and also fixed it in place with staples (of the staple gun variety ... bout for about $20 from Bunnings for another long ago project).
Once the glue had set I drilled 4 holes and thread 4mm bungee cord through, pulled tight(ish) with a knot tied at each to hold it in place. The purpose of this is simply a hanging rail for things like rags and tea towels. It may look off centre ... well it is ... but with where I intend placing the table it is actually centered and it should be covered about an inch either end with a gap on the left to mount a fire extinguisher or torch TBD. This should make itself apparent when I actually get to building the table. As the plugs were no good for attaching the new trim I just though F#&% It and used some self tappers. Point to note, don't use long screws at the bottom or you'll peirce the water tank for the rear washer (I stopped myself before it happened :shock: ).
Ignore the red dots, these are my son's crayons used to mark where the existing holes are in the metal behind the trim :P
I'll update as things progress ...
UPDATE: 02 October 2010
Ok, So finally got off my A$$ and finished the job. Unfortunately I got too focused on finishing that I didn't take many pics. In Hindsight I don't think they are needed. Here are three images that show the completed table. The first folded up and secured in place, the second shows a close up of the hardware I used and the last shows the table folded out. If anyone has any questions about any of it let me know otherwise, hope it helps with ideas for anyone else doing a rear door table.
When I bought my 2nd hand 90 Series RV, it had a damaged rear door trim. It had a small tear and the elastic to both pockets was shot. I'd rung around to source a replacement trim but the only wrecker I could find that had one was in Tassie of all places. I read many forums/posts that described and pictured tables being made to bolt to the existing trim that fold down ... I decided to go that step further and replace the rear trim as well as build the fold down table.
Now I know this has probably been done to death, however, I'm sure the server isn't struggling that much for space and maybe some of the minor things I do different to other my give some an idea or two for their own build up.
So far I have only finished the trim to replace the old one and am yet to build the table. I will update the thread (this first post) as I go with new images and notes.
Thanks to all for the inspiration and ideas ... so here goes!
I started off by removing the upper trim (below the window, above the door trim) which is clipped in by 4 or 5 clips along the front edge, I then simply pulled the trim off with a little muscle. There are plugs around the outside holding the trim on, my intention was to use these to fit the new trim ... but ... the 4.8mm masonite I was using was too think so I just pushed on to cross that problem later. I laid the old trim on the masonite and carefully traced out the outer edge, the door handle, washer refil access hole and holes for the grab handle. Next ... the power tools :twisted:
I used a jig saw and drill to cut out the trim, cutting ON the line so as not to leave the trim too big to fit the door. I used a electrice palm sander to clean up the edges and gave it all a wipe down to get ride of dust reading for glueing.
I used a marine grade carpet from Bunnings adhered with a high strength spray on adhesive from Clark Rubber. I trimmed the carpet at the edge of the holes for the door latch and refill access as once again, due to the thickness of the masonite and carpet, it would have been a problem getting things to fit with the extra layer of carpet had I folded it over the edges. For the outer edges I folded the carpet over and gave it a heavy dose of the adhesive and also fixed it in place with staples (of the staple gun variety ... bout for about $20 from Bunnings for another long ago project).
Once the glue had set I drilled 4 holes and thread 4mm bungee cord through, pulled tight(ish) with a knot tied at each to hold it in place. The purpose of this is simply a hanging rail for things like rags and tea towels. It may look off centre ... well it is ... but with where I intend placing the table it is actually centered and it should be covered about an inch either end with a gap on the left to mount a fire extinguisher or torch TBD. This should make itself apparent when I actually get to building the table. As the plugs were no good for attaching the new trim I just though F#&% It and used some self tappers. Point to note, don't use long screws at the bottom or you'll peirce the water tank for the rear washer (I stopped myself before it happened :shock: ).
Ignore the red dots, these are my son's crayons used to mark where the existing holes are in the metal behind the trim :P
I'll update as things progress ...
UPDATE: 02 October 2010
Ok, So finally got off my A$$ and finished the job. Unfortunately I got too focused on finishing that I didn't take many pics. In Hindsight I don't think they are needed. Here are three images that show the completed table. The first folded up and secured in place, the second shows a close up of the hardware I used and the last shows the table folded out. If anyone has any questions about any of it let me know otherwise, hope it helps with ideas for anyone else doing a rear door table.
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