JayCo Popup Rebuild (Pictures)

Discussion in 'Camper Restoration Projects' started by DFire2, Jun 20, 2016.

  1. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Most of it will be covered up by either cushions or cabinets. So with the damage that happened, it's not that bad.

    If you want fanciness. Just use a table saw with the very low cut and make your own "beadboard" out of plywood panels.
     
    Rideswithchrist likes this.
  2. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    So I got started on the cabinets...they came out a little more "reinforced" than I wanted, but still weight wasn't too bad...

    First, I got out the 1/2" ACX plywood and started some doodling...
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    Then the cutting...
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    And just to make sure I'm satisfied with my design...yup, we're good. :)
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    And reinforcing, which will used for inner walls, drawer supports, and counter support...
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    And the final assembly, still have to get a new fire extinguisher, ours expired in...take a guess...1994
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  3. Rideswithchrist

    Rideswithchrist Member

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    Jan 18, 2016
    Buda, TX
    That's a good idea- like shiplap!
     
  4. Rideswithchrist

    Rideswithchrist Member

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    Jan 18, 2016
    Buda, TX

    I didn't go back and look, did you keep the same layout for the cabinets?
     
  5. smalt4

    smalt4 New Member

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    Jun 29, 2008
    Totally amazing! I LOVE seeing the progress in pictures. We have a 1994 Jayco but nowhere near your talent.
     
  6. fastdixie

    fastdixie Member

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    Dec 2, 2014
    Nice progress, liking your repair ideas!
     
  7. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    No, cabinet layout and design is all new. See OP for layout change.

    I really want to finish the cabinets tomorrow, even get the countertops done if possible. Just mapping out on paper my plywood cutting diagrams to get the most out of wood.
     
  8. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Cabinet progress for today...

    I went to Home Depot and got another sheet of 1/2" Sanded Ply and a bundle of 2x2's. I already had the plans down for cutting, so I let HD to the majority of for me ;)

    Then I decided on my drawer, fridge, and cabinet door dimensions, and started drilling my corner holes.
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    Then got out my jigsaw and finished my cutouts...
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    Almost forgot I had plans to install an outlet in this panel, the cut came out really well. Used a spare piece of 2x2 and ply to use as anchors for the brads, some didn't do in all the way >.<
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    Then added my studs...
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    And this panel is finished! Moreless...
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    Next was to get the other pieces put together to complete this whole assembly...
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    I made some support pieces out of more spare 2x2's and ply, just something to make sure it all squares up and gives me support for gluing and nailing.
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    Then used some other 2x2 scrap to give me enough clearance to clamp the panels together...
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    After getting the two assemblies fitted together, I decided not to join them yet because they need to be painted and everything. If joined permanently, I wouldn't be able to get them out of the camper, ^_^

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    I unforunately didn't get to building the other bench seat and finishing the first one. Planning to head back out tomorrow and get those done, maybe even get the electrical mounted, too. Here's hoping!
     
    Mamie likes this.
  9. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    And now today's progress...big bench seat complete!

    Here it is with the back and top supports done.
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    And with the tops on it, just normal 1/2" ply, no sanded. Drilled finger holes, too.
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    Then I got started on building the other bench seat, connected to the cabinets...

    Panel and studs laid out.
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    After this piece was put together, I had enough time to cut the side panel and glue/brad it to the front panel.
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    Oh, and I forgot to make the notches for the cables, not all of them came out correct, I'll fix them later.
     
  10. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Didn't get a whole lot done today, because I had a family lunch during my "camper time".

    Today I worked on getting the small bench complete. I quickly realize I screwed up with my supports, they were supposed to be offset 1/2" down to accommodate for the "lid". So I decided to use my circular saw and my new (bought 3mths ago, haven't used til now) multi-tool to get the necessary slot.
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    Then I had to cut and mount the back brace...
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    And then there's the inner supports, which I screwed up the outside one. As you can see, the the support hits the corner one, but that's an easy fix ;)
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    And a view from the door...
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  11. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    I forgot to post progress pictures from a couple days ago...

    I forgot to show pictures of the cutouts for the lift cables...
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    I wanted to see how the cushions colors looked against the wall and floors, I like it! Oh, my daughter decided she wanted in on it, too.
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    Ok, now to finish that half bench seat!
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    Now it's time to start on the drawers!! Getting all my measurements wrote out...
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    I ended up getting the board pieces cut for the 3 drawers on the door-side cabinet. I have to go to Home Depot and get a sheet of 1/8" hardboard (at least I think that's what it's called). Only ~$8 for 4'x8' sheet.

    NOTE: I had plans to do some French Cleat style drawer sliders, but figured that was a little much I thought, so I'm gonna go with some basic wood sliders.

    I won't be able to resume anymore camper work until Monday, stay tuned!
     
  12. jmatasov

    jmatasov "Never tell me the odds." -Han Solo

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    Aug 19, 2016
    Western NY
    Great job on the rebuild! How does the "hardboard" differ from plywood?
     
  13. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Price for one. A whole sheet (4x8) of hardboard is less than $8. And it's true 1/8". I gotta do my progress post from yesterday yet...
     
  14. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Yesterday's progress...

    So I didn't get a whole lot done yesterday. Just finished making all my drawer box pieces.
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    And making the slots...
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    Taking a break today (my Friday). Back working on it Wednesday!
     
  15. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Drawer day!

    Here is a look at my "paperwork" for these drawers...
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    First thing I did was cut up my 4x8 sheet of hardboard to get my drawer bottoms...
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    I sanded the edges of each drawer bottom so it would fit better in the slots...
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    And the first drawer assembly, SUCCESS!!
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    I have this drawer at home (think it came outta a computer desk where the slider slot was embeded right in the drawer sides...so thought I would do the same!

    Question for everyone, have you ever seen a dado blade like this? My dad says they aren't made anymore. Made by DeWalt
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    And I had to make my own blade shield (that's the name, right?) for the new dado cut 3/4" width...
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    And this is the end result after successful testing!
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    And I used a 3/4" test piece to make sure the dado cut functioned the way I wanted...
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    All drawers now assembled and slotted!
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    And then testing the fit. I cut the drawer openings a 1/2" bigger on the sides, 1/4" on top and bottom. I figured I could make some skinny sliders and still be able to have enough support to hold the drawers with some weight, I made the sliders 3/4" (slot width) by 5/8" (1/2" gap plus 1/8" for fine tuning and sand-ability).
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    Oh, and here's a panorama photo of the inside so far...
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    Well that's it for today, back at it tomorrow. Plan on building all the cabinet supports, dividers, and drawer slides! Then it's onto cabinet doors and painting, and then countertops! Woohoo! I love progress!
     
    Last edited: Jul 28, 2017
    Mamie and jmatasov like this.
  16. jmatasov

    jmatasov "Never tell me the odds." -Han Solo

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    Aug 19, 2016
    Western NY
    Nice job! Will the drawers open while the camper is moving or do you have a latch or something for them?
     
  17. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Still in the R&D process for the latches, but I have an idea.
     
  18. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    So didn't get much done today, just a LOT of sanding. Also went and bought a sample paint can to test out the cabinet color before investing $42 for the whole gallon (sample cost $5). The color is called "Sandstone Cliff" by Behr (Home Depot).
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    And I wanted to see what the colors looked like against each other...
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    Also got a block of wood to use for my breaker box mount.
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    Maybe tomorrow I'll get the paint and go to work on the cabinet panels.
     
  19. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    Got a lot done today. I finished sanding the last cabinet (i missed one), and got it ready for paint, which was done TODAY!

    Went to Home Depot, got my "Sandstone Cliff" Behr paint, also a can of the Rust-o-leum "Burnished Amber" paint, and also a spray can of some Thompson's Waterseal, pictured below...
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    Also picked some some 98 cent knobs for the doors and drawers, only 3 for now, just to make sure they turned out good. I am re-using the fire extinguisher fixture, so I got that cleaned and painted. Also the screws to hold it in.
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    All cabinets painted!! Woohoo!
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    Also sprayed the inside with the waterseal, so hopefully no warping will occur after time.
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    I could NOT find any inset hinges @ Home Depot, blah. But my dad found me a whole bunch in his pole barn!
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    ...and painted!
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    I also almost forgot to make my cutouts for the other outlet and fire extinguisher placements...
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    And end of the day photos...
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  20. DFire2

    DFire2 Member

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    Jun 18, 2016
    Central Michigan
    So today the wife came with me to help out. I think she got more done than me, lol.

    I got to work cutting out the cabinet doors and drawer faces out of my last sheet of 1/2" sanded ply.

    All this was being done while she sprayed down the drawers with the waterseal.
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    The after they were cut, she sanded them down to be ready for paint.

    I got a new tool today, Ryobi cordless router and bit set
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    This thing is simply awesome, 29,000 RPM, it cuts the wood edges like butter, so I made a test piece to test it out first...
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    My wife also started spraying on the chalkboard paint to the door screen covers. It will make a nice memo board!
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    Also started piecing together the bed step that covers some lift runners and cables.
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