Another remodelling project

Many of you have heard Lorna's complaints about the dashboard in the Endeavor.  The complaints were valid, no flat spot anywhere and a bulge in the middle that obstructed the driver's view of the right front, making a blind spot.  While in Elkhart, IN, getting the bedroom floor done in laminate we were referred by Bradd at Bradd&Hall to a local Amish woodworker, Carlyle at Focal Wood Products.  We drove the motorhome to his shop in Nappanee on Monday to see if he could do something with the dash.  After some study and discussing various ideas he agreed to do the job.  He was the first person we've asked about this project that was interested, as it's not an easy job.

On Tuesday, we arrived at his shop at about 1300 and he went right to work with a Sawzall, saber saw and small rotary saw and removed the top of the dashboard.  He made numerous measurements and starting cutting the wood for the various parts.  On Wednesday, we came back at 0730 and he had most of the pieces cut and ready for fitting.  Of course there were a lot of things that showed up during this process that required some modifications and we also came up with a few other ideas to incorporate as well.  Carlyle took all of this in stride and accommodated every change.  Today, Thursday, we went back about 0830 as he had to finish the staining and varnishing this morning before the final assembly.  This took the rest of the morning and we were done before noon.

The last photo below is of a steering wheel table we bought at Bradd&Hall that was made by Carlyle.  We didn't know that when we bought it, however.

We have been staying at the Pla-Mor Campground just west of Nappanee with excellent WiFi internet service and a satellite friendly site with full hookups.

See the attached photos for the progression of the project.  We're rapidly running out of things to improve in our motorhome and we expect to enjoy it for many more years.

Excellent job Ned and Lorna! Now, with all that flat space, Lorna won't have any excuses to not drive and play Solitaire at the same time! They really do nice work.

No they, just one man, with a very well equipped wood working shop.  Being Amish, it's all run from a generator.

Very nice.

Looks great!  Why is that high arch on the driver's side?

Steve

If you ever need an Amish machine Shop, I know a good one NE of Topeka IN.

They saved our Starcraft plant in Listowel, On, Cn, their production run sch'd 13 weeks later when I searched and found them. The somehow had a phone booth on the dirt country road across from their gravity generator run facility.

In 4 weeks they manf the U-bolts for the tent camper springs --a 16 week lead item. It was 3x's the cost but kept the factory open. The PA got a black mark from his manager up there and it was deserved.

Steve, the arch is because the dash is molded fiberglass and he had to match the curve.  We couldn't cut any lower without major problems.

Thanks Ned, I just didn't notice the arch in pre-construction photos.  I like the slide-out for the laptop!

Steve

Ned,

I like it, nice job!  Looks like the air duct located (by what I call the 'glove compartment') got cut.  Were you able to patch it together or what?  Is the blind spot still there for the driver or has it been reduced in size?  And the table over the steering wheel, does it take up a lot of room when stored? 

Now I'm wondering if we can do something like that with ours.  Thanks for the pictures and commentary; good food for thought.

Looks real nice.

Looks like he cut about 3 inches off of the dashboard above the passenger side glove box.  And then added the oak panel to cover the glove box opening and maybe strengthen/stabilize  the slide shelf above it??  Is there a lock of some sort on the lap top computer sliding shelf to keep it from moving when you are on the road?

Really looks great.  Joanne has wanted something similar on the passenger side of our van dashboard.  I haven't done it yet partly because of the air bag that is in the "glove box" location.

Rolf, there was enough excess in the duct to cut it off and reattach it to the outlet.  The blind spot caused by the dash is gone, but there is still a blind spot, but the view is much better.  At least Lorna says it is   We'll find out about storing the table today as this is the first day back on the road since we got it.  We could put it on the couch, but the dog might object as that's her travel spot.  We may just lay it on the bed.

Len, exactly right, about 3".  We lost the glove box but it was just a junk catcher anyway.  The computer used to ride on the lid.  The dash is 1/4" molded fiberglass and pretty stiff, and the whole assembly is quite secure.  We haven't decided how we might secure the shelf when traveling.  I'll be thinking about that today but I have some ideas.  The slides are stiff and it may not be an immediate problem.

A passenger side air bag would severely limit your options.  And a van would have a smaller dash area to work with.  Have you looked at the Jotto desks?

Nice looking remodel.  That guy did a great job for you.

The new table for the computer worked very well today on the road, but I do have to find a way to secure it so it doesn't slide to and fro.  I have an idea but it will take a drill press to do it.  Meanwhile, I'm thinking about other methods.

Industrial grade velcro might work.

Velcro won't solve this problem.  The tray needs to be able to slide, yet be stopped in any position.  I'm thinking of drilling holes along one edge at some interval (2" perhaps) with a matching hole in the lower board and using a pin to secure the sliding portion at any of those intervals.  Not the neatest solution but the best I've come up with so far.  For now, I just let it slide, giving no end of amusement to Lorna

Ned, this is pictorial of how I secured my shelf in any chosen position.  The detente's can be notches, holes or any design you like.

That's quite creative Lou.

Carlyle did our table/computer desk modification.  He certainly does excellent work.  He told me he used to be in QA at Newmar. 

Interesting technique, Lou.  I'll have to think about that.  It will take more than just a drill press to do however

Ned & Lorna,

When you decided to remodel what steps did you go through?  What sort of thinking went into remodeling versus purchasing another rig?  I really like the work, very impressive.
Phil