Work Done on the Bunk

So as of Friday I had all kinds of ideas floating around in my head on how I was going to build out the forward bunk. After Googling 'bunk design' and looking through dozens of pictures of all kinds of bunk beds, I came across one used in a yacht. As I was waiting for a meeting to get started, a flipped over a sheet of paper and sketched out my idea ...

The design called for a single solid board that rose up just above the height of the mattress. At one end of the bunk the edge drops down low, allowing for the occupant to climb in and out. Here I've set the access on the left side. I've sketched a short, two step ladder leading up to the bunk. It's located in front of the A/C. This seemed like the best place to put the ladder. In the center at the bottom, the board has a lower section - the two small boxes next to the ladder are the power receptacles, and the long slot is for a small pull-out table. The idea for the table is that it will stick out just a bit when 'retracted' - creating a small shelf to put drinks or a cell phone, but can be pulled out to serve as a small dining table. This left the entire space below the bunk open for storage.

Saturday it was back to Lowes for materials. I finished the 'lifting strap' and attached it to the futon seat back. It works well, although there is a bit of technique to raising the seat back that requires some muscle. I also installed a couple D-Rings in the floor as anchor points for the A/C. I had purchased a bungee that was rated for the length needed to wrap around the A/C, but despite using every bit of my strength to stretch it around the top of the unit, it was about an inch short. I settled on using an old cam buckle tie down, and as a measure intended to cushion the air conditioner, I fashioned some foam suspension out of two lengths of hardwood dowel shrouded in 1" foam pipe insulation, and positioned these under the A/C. With the tie down snug, there is a little give and spring to help with bumps while traveling. I figure that while it was a portable A/C unit, it probably wasn't designed with this purpose in mind.

While at Lowes I picked up the wood and hardware needed to build out the bunk. I first installed some blocking underneath for the table slide rails. I also cut the table from a 2 x 2 section of 5/8" birch plywood - not unlike what is used in the walls. I put a few coats of poly on it in between other tasks. I finished up Saturday with the rails installed, and the power receptacle moved a few inches to the left.

Sunday morning I started back on the table - I wanted to get the extension part right and confirm the dimensions for the slot in the bunk board. I attached the table rails and slid it in - works beautifully and the shelf extension is perfect. Fully extended, one can sit on the futon and use the table without having to lean forward. 

After cutting the bunk board to the correct width, I installed some blocking on the inside edges at the ends. The blocking allowed the board to sit at the correct height when dry fitted to the bunk frame. This made it easier to clamp it in and set my register marks for the slot, receptacles, and lower edges. Then came the jigsaw work, which was tricky given that mine isn't very precise. But I hedged my cuts a bit and was able to clean up the edges with the power sander. I dry fitted the board again and confirmed my cutouts were aligned properly. The last cut was for the bunk access 'drop down'. The blocking on this end was just screwed in (no glue) to provide temporary support. I removed it, made my cut and then sanded down the edges on both sides. One last dry fit check, then I applied the glue, leveled and clamped in the board, then drilled and screwed it to the frame.

Have a look at the results ...

I installed buttons in the screw holes to clean it up a bit. I'll use a light stain on the bunk board to match the color of the walls, followed by several coats of poly.

You can see the cut out for the receptacles and the slot for the table. I'm going to try to trim a plastic cover down so that it fits cleanly in the cutout. Also the table is shown in the 'shelf' position.

Table fully extended. The rails are rated at 75 pounds - plenty of strength for a couple place settings, a coffee pot or laptop.

Judging by that face I believe we have the coveted 'kid's seal of approval'. Snug as a bug in a rug!

Over next week - staining and finishing the bunk board. Next weekend - building the ladder, installing the TV, possibly fabbing the 'bike cleat', and maybe getting around to building 'Mr. Stinky', the camp toilet. I'll save that task for last!