I was very stupid and when getting my van initially, I threw out the original shelf that was over the top of the cab. My buddy Calum kindly said he would help me make a new one, along with a bulkhead to prop it up.
I decided to fully close off the cab for security and for heat saving reasons. The process was very similar to the flooring, where we fixed together a timber frame and the fixed some hardwood ply to one side. I think cut insulation board to fit in the gaps.
We also managed to salvage some free carpet panels and stuck them to the shelf and the ply.
If you have any questions feel free to leave a comment below.
Link to Blog for more info: https://www.greenhorncountryclub.co.uk/post/bulkhead
Materials used:
2 sheets of 6mm ply - https://www.buildbase.co.uk/timber-doors-sheet-material/sheet-material/mdf-board/mdf-timber-sheet-2440x1220x6mm-standard-mdf-board-100008916-2802246
1 sheet of 9mm ply - https://www.travisperkins.co.uk/plywood/structural-hardwood-plywood-2440-x-1220-x-9mm/p/670591
8 lengths of 3x2 timber - https://www.travisperkins.co.uk/treated-timber/c16-kiln-dried-regularised-sawn-treated-timber-47mm-x-75mm-x3m/p/206913
1 sheet of 50mm insulation - https://www.wickes.co.uk/Iko-Enertherm-PIR-Insulation-Board-2400-X-1200-X-50mm/p/234898
Spray adhesive - https://www.sealantsandtoolsdirect.co.uk/everbuild-stick-2-spray-contact-adhesive-500ml-conspray5
TOTAL SPEND: £243.27
More content at: https://www.greenhorncountryclub.co.uk
Follow on Instagram: https://bit.ly/3sEasQG
Chapters:
00:00 - Intro
01:29 - Timber frame
04:48 - Fixing ply
06:43 - Cutting insulation
07:22 - Carpeting
08:54 - Fixing to the floor
09:26 - Fitting insulation
09:58 - Double-layering the shelf
11:34 - More carpeting
12:23 - End result