Van Build 2.0 VLOG - How to cut complex shapes and update on current progress

[@jeffclark862]

That looks great! Cardboard templates work well for complex cuts and curves. I have done it on a couple of projects. Taping a few pieces together makes it easier.

[@EndgameCampers]

Thanks for the tip!

[@JonnyDIY]

That cabinet sure did turn out nice. Look forward to seeing your creative back drawer kitchen system 👍 stay cool! Well try at least 😆

[@EndgameCampers]

Thanks Jonny!

[@davidpatrick1813]

I called the company that is the one for your solar controller. Their technical support said those will work okay for LiFePO4 and you can it won't hurt or shorten the life. I have an older solar controller from the same company .. that I don't know what I'll use it for ... my systems (3 systems) all use Victron ... I am very happy with them.

[@EndgameCampers]

Thanks. For now the golf cart batteries work well, but if they fail, I’ll definitely go lithium. Thanks for the info.

[@jerrytalley802]

Dave, great idea on the back kitchen. Could you put a small, retractable awning back there to shed the rain, maybe leave doors open, or when they are cooking, shade and/or shelter?

[@EndgameCampers]

Great idea. Thanks my friend

[@paulsenecal98]

Thanks for posting this video, I learned some tips for cutting out shapes for cabinets ect.in my mini van. I really think that shaping tool will help a lot with what I need to cut.

[@EndgameCampers]

Glad it was helpful!

[@jaypence1911]

Looks nice in there, cabinet stands out nice!

[@rickkempsell5076]

Dave, you can also use what’s called a “joggle stick” or “tick stick” method for mapping out complex shapes. They’re used when mapping out cuts on sailboat bulkheads and such, which of course have some difficult shapes to work with. There are some examples on YT on how to do so. Thanks for your time and effort to make these videos!

[@EndgameCampers]

Thanks Rick for the tip. I’ll look into it.

[@stephaniedill9966]

To copy a big contour, make up a big compass . For example you could use a yard stick cut in half or those paint stir sticks. Lay them on top of each other and screw or rivet them together at one end so you can open a close them like a compass. On the bottom ends on one side attach something pointed like an awl or ice pick, on the other end attach a pencil. The idea is to make a pattern so use a piece of plywood that is wide enough and tall enough to fit the curves of the contour that you're copying. Qnce you know how wide open the compass nees to be then attach a piece of wood across the compass to keep it at that width. Then just follow the contour with the pointed end and the pencil end will draw the shape. I learned this when I was hanging around wooden boat builders...there nothing flat or square in a sailboat. Hope this helps.

[@EndgameCampers]

Great technique. Thanks!

[@stephaniedill9966]

And Thank you for sharing your ideas and awesome wood work. Really appreciate you tubers like you.

[@Tryagain205]

Hey Dave. Retired builder of luxury yachts here. The best way that I’ve ever seen to duplicate complex shapes is to take a sheet of thin door skin and rip strips at 1” Then cut the strips on your chop saw at 4-6” long. Apply 2” wide blue masking tape onto the wall where you want your bulkhead pattern to be. Mark on the blue tape the exact location of the bulkhead. Take your pieces of thin plywood that you cut and use a hot melt glue gun to “spot-weld” the edge of the first piece of plywood to the wall. Take the next piece and lap joint with a one inch overlap to the first piece. Continue adding pieces of the thin plywood in an alternating fashion so that when you remove your pattern it stays flat. When you get to a sharper corner you can cut or sand a small piece perfectly to fit and then hot glue into place with a lap joint. This process is very fast and very accurate once you get going. You can add gussets and cross braces quickly and easily in order to keep the pattern true and add “spot-welds” easily and quickly where needed. Once the pattern is finished it is easy to pull the pattern off by gently pulling on the spot welds and now you have a perfect pattern. This would take about ten minutes to accomplish with the example you provided. You can even add door openings, hinge locations and holes where you want them. Hope this helps. Thank you for your terrific videos and keep up the fantastic work!

[@EndgameCampers]

That is clever… thank you so much! I think these comments are more useful than the video. I’m good with that!

[@jerrytalley802]

Dave, I was one of the ones that asked about patterns too. I was thinking how great it would be if they made a 3-4’ super gauge, or make on expandable one for van builds. Maybe it’s a great idea for a new tool. Yours with skewers closer together would be a simple but great idea, thanks.

[@EndgameCampers]

I’ll check it out

[@jerrytalley802]

Dave, I have a suggestion; each build you do, measure your finished cabinets and draw it up in case you ever want to make another one. Imagine if you got another van like this one, it would save a boat load of time. I had a high top van once with the seat/bed setup, but I never thought about your cabinet idea, may not have kept it long enough.

[@davidpatrick1813]

Groovy

[@0HARE]

I sure admire your design and fabrication work there. I wondering how much trouble you have with mosquitos there in that desert environment. Over here in Texas, the mosquitos would eat you alive if you tried to do much outdoors after about 6:00 - 7:00pm.

[@EndgameCampers]

I’m fortunate, no real mosquito issues out here. Thanks my friend. Happy travels

[@duane4972]

There is a much quicker and easier way to make a pattern. Unfortunately it is too hard to explain here. I'll try later when I have time.

[@EndgameCampers]

Ok, thanks