I don't have any experience with woodworking but I'm in the process of converting a Nissan NV2500 High Roof van into a campervan and I want to work on adding a kitchenette, cabinets, a closet and a bed frame.
I searched online about the proper plywood (I'm using Birch Plywood) thickness for making cabinets and I saw suggestions to use 1/2" and 3/4", I was planning on bolting all the structures to the steel frame of the van using rivnuts (possibly plusnuts) and bolts so none of them will have to support their own weight.
My question is do I need to use such a thick plywood or can I get away with 1/4" since it'll be bolted to the frame?
LMAO. Good one. No, it won't tip over unless you build the cabinets on stilts over the roof of the van.
Look into foam core products. You can get foam core plywood that's structurally sound, works much like regular plywood and weighs a fraction as much.
If that's too costly, you can build panels yourself with 1/2" strips of plywood for a frame and sandwich that between two 1/8" plywood sheets. Glue small squares of 1/2" plywood as needed in the core of the panel as needed for stiffness.
It's a 3/4 ton van… I wouldn't be too worried about the weight of the cabinets. 1/2" birch (if its veneer core) is pretty light, I'd use that. Just stay away from the MDF core, that stuff is much heavier. But in my experience, 1/2" is most often plycore, so you should be good
Even though the van can handle the weight, I still think doing some things to reduce the weight like I mentioned in my previous post makes sense. If it's going to be used as a camper, fuel economy and performance on steep grades - both acceleration and braking - should be taken into account.
I looked into the foam core and it's currently outside of my budget so I'll stick to the plywood.
If that's too costly, you can build panels yourself with 1/2" strips of plywood for a frame and sandwich that between two 1/8" plywood sheets. Glue small squares of 1/2" plywood as needed in the core of the panel as needed for stiffness.
Folks make stuff out of thin plywood on boats all the time.
The key is to bend it a bit to put a bit of stress in it then glass or epoxy it.
Or you could use even thinner stuff with torsion box design parameters.
As others have mentioned, weight is going to be a large factor in what you do.
With proper joinery methods, even 3/8" VC plywood can be fairly structural. (1/8" ply backs dadoed into 3/8" ends for example)
If you go less than that, a system of cleats and frames is usually implemented.
While foam core is lighter, a basic veneer core plywood will still be fairly light.
3/4" thick doors are often simple frames with 1/8" front panel only.
You can't think of these cabinets like ordinary cabinets anymore.
There is RV-style hardware that secures drawers and doors while the vehicle is moving, etc.
It is an entirely different critter than your kitchen cabinets at home.
I can't tell you much about weight advantages of cedar, but unless you're planning to live in the van it does seem that some of it would help keep things from getting musty when it's closed up waiting for your next trip. Even just blocks scattered around in cabinets.
I think 1/2 inch birch ply for the structural parts, 1/4 for backs and drawer bottoms, and I'd go with 1/2 inch solid wood frame doors with 1/4 inch panels. Exposed sides should be 1/2 inch, enclosed sides (between cabinets) can be 1/4 inch.
The mention of boats should recognize we use marine ply, no voids, exterior glue. A van may have moisture inside from time to time due to condensation, so you are looking for a long term deal, consider some moisture resistant materials. I would be a shame if 5 years from now, after a wet camping trip, some of the panels begin to delaminate.
If that s too costly, you can build panels yourself with 1/2" strips of plywood for a frame and sandwich that between two 1/8" plywood sheets. Glue small squares of 1/2" plywood as needed in the core of the panel as needed for stiffness.
I really like this suggestion. It is a bit time consuming, but will definitely save you some weight.
This is an older thread, you may not receive a response, and could be reviving an old thread. Please consider creating a new thread.
Related Threads
?
?
?
?
?
LumberJocks Woodworking Forum
2.5M posts
96K members
Since 2006
A forum community dedicated to professional woodworkers and enthusiasts. Come join the discussion about shop safety, wood, carpentry, lumber, finishing, tools, machinery, woodworking related topics, styles, scales, reviews, accessories, classifieds, and more!