Expedition truck cabinets..

[Dusty.House]

Hey all,

I’m looking for a recommendation on building cabinets for an expedition truck I am building (@dusty.eva on IG). I need to build 14 of various sizes.

My goals are :
- lightweight
- tolerant to humidity changes (no MDF)
- tolerant to vibrations (no chip board)
- look awesome
- using materials I can get in Seattle area

My current thought is to use 1/2” plywood, a real wood edge with a Formica laminate. For large pieces I plan to use my CNC to route out recesses to further reduce weights.

Ideally I’d like to use domino’s but I believe that doesn’t work with 1/2”.

I’d love to get some thoughts on materials and assembly.

Thanks!

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[Packard]

Perhaps MDO?
https://www.capitolcitylumber.com/product/mdo-medium-density-overlay-signboard/

MDO, also known as Signboard, is an exterior-grade plywood with a high-quality fiber surface saturated with phenolic resin solids.  The plywood below the fiber face is smooth, clear and free of patches, providing a smooth surface with minimal grain showing through.  MDO plywood is water-proof and weather-resistant.  This plywood is often used for exterior signs.  MDO plywood can be sawn, nailed, routed, shaped and drilled.  Although this product is designed for exterior use, it works well inside the home in areas that need to be smooth and hold up well to moisture.  This product resists inclement weather areas well.  It is often used for exterior signs and sub-board underneath laminates for countertops…
https://www.google.com/search?q=medium+density+overlay+seattle&client=firefox-b-1-m&ei=ViyVY9QJrNnK0w_Z2YLoCA&oq=medium+density+overlay+seatle&gs_lcp=Cgxnd3Mtd2l6LXNlcnAQARgAMgQIIRAKOgoIABBHENYEELADOg0ILhDHARDRAxCwAxBDOgcIABCwAxBDOgUIABCABDoECAAQQzoFCAAQhgM6BQghEKABOgUIIRCrAjoFCAAQogRKBAhBGABKBAhGGABQvBRYz1xg_XdoAXABeACAAW6IAaoEkgEDNi4xmAEAoAEByAEKwAEB&sclient=gws-wiz-serp

 

[Dusty.House]

Perhaps MDO?

Cool thanks, I'll check that out!

 

[xedos]

Ideally I’d like to use domino’s but I believe that doesn’t work with 1/2”.

4mm dominos are fine in 1/2" - 12mm sheet goods.

How about pvc sheets for the boxes ?
https://www.homedepot.com/p/1-2-in-...8FbSp9SuiA1sD1vS6KBoCMWAQAvD_BwE&gclsrc=aw.ds

For the ne plus ultra , order some carbon fiber panels - but get your checkbook ready cause a 4x8 sheet is gonna run you a couple of thousand bucks.  It ticks all the boxes on your list though.

 

[Dusty.House]

4mm dominos are fine in 1/2" - 12mm sheet goods.

How about pvc sheets for the boxes ?

Oh well that solves one problem, I wanted something hidden, rather than using staples or pocket screws.

Would pvc sheets feel cheap? I want lightweight, but given the investment I am making I want it to look really good... I'll check them out when I go to HomeDepot.

 

[RussellS]

Since you are in Seattle, take a trip down to the docks or boat area and look at what is used on the boats.  Or stop by a shop that specializes in boat interiors.  Look at what they are selling for installation in boats.  Your description is similar to what boats use.  I'm not sure humidity is too much of a concern.  It will not be exposed to weather since it will be the inside of a vehicle.  And humidity inside a vehicle never gets like the outside.  I would guess almost any wood should work fine.  Or plywood.  Or MDF, particleboard.

 

[Dusty.House]

Since you are in Seattle, take a trip down to the docks or boat area and look at what is used on the boats.  Or stop by a shop that specializes in boat interiors.  Look at what they are selling for installation in boats.  Your description is similar to what boats use.  I'm not sure humidity is too much of a concern.  It will not be exposed to weather since it will be the inside of a vehicle.  And humidity inside a vehicle never gets like the outside.  I would guess almost any wood should work fine.  Or plywood.  Or MDF, particleboard.

That's a great idea thank you! It is very similar to a boat yes!

 

[Mini Me]

Have a look through this search link using 20 series extrusion. If I used this all fasteners would have Loctite on them for the final assembly, corrugations on dirt roads will shake anything to bits if precautions are not taken.
https://www.youtube.com/results?search_query=20+series+extrusion+cabinets

 

[Sparktrician]

I'm going to suggest that before doing anything, take a trip down to Bend, OR, and visit Outside Van.  Find out how they build to purpose.  1/2" plywood seems very flimsy for a true expedition truck.  There are far better options.

 

[xedos]

Since you are in Seattle, take a trip down to the docks or boat area and look at what is used on the boats.  Or stop by a shop that specializes in boat interiors.  Look at what they are selling for installation in boats.  Your description is similar to what boats use.  I'm not sure humidity is too much of a concern.  It will not be exposed to weather since it will be the inside of a vehicle.  And humidity inside a vehicle never gets like the outside.  I would guess almost any wood should work fine.  Or plywood.  Or MDF, particleboard.

That's a great idea thank you! It is very similar to a boat yes!

They'll be using marine grade ply - which is crazy heavy.

 

[Michael Kellough]

Have a look through this search link using 20 series extrusion. If I used this all fasteners would have Loctite on them for the final assembly, corrugations on dirt roads will shake anything to bits if precautions are not taken.
http://www.youtube.com/results?search_query=20+series+extrusion+cabinets

On 8020 extrusion T slots the top of the T is sprung in toward the bottom of the slot. In theory when a fastener is tightened the top of the T is tensioned and that is supposed to eliminate the need for lock washers etc. Does it work in practice?

 

[woodbutcherbower]

Just thought I'd share this - it's a future expedition vehicle which a buddy of mine has just bought from a specialist ex-military vehicle company in the Czech Republic. ([member=61254]mino[/member] - Mortar Investments in Prague). It's an ex-Russian Army Ural 4320, fitted with a Kung quad-insulated box body formerly housing radio equipment. All of the stuff at the front of the box is a state-of-the-art air filtration system, plus a night heating system which runs on diesel. The truck is full-time 6WD with diff and cross locks, and it has a central tyre inflation system for sand and deep mud. Power comes from a 10.8-litre V8 diesel which does around 6 miles to the gallon and makes the most unbelievably beautiful sound. The truck was designed to be bombproof in service whilst being abused by Russian conscripts in all former Soviet zones from the Ural desert (120F in the summer) to places like Yakutsk in Siberia (-70F in the winter). It has a system on the engine and tanks which pre-heats the oil, fuel and other fluids so the engine will start first time even in those conditions. It's built like a battleship - no electronics whatsoever, everything's run using mechanical linkages, cables and big chunks of steel for easy repair in the field. The picture doesn't really do the size of it justice - it's HUGE. He let me have a drive of it round the yard of his farm - it was like driving a small town on wheels  [big grin]

They have another one for sale (only 1,800km on the clock !!) if anyone feels like a retirement adventure ......https://mortarinvestments.eu/catalog/onStock/ural-4320-diesel-shelter-1800-km

Good luck with your project !!

[attachimg=1]

 

[Packard]

I thought he was talking about a Ford.

 

[semenza]

What is the base vehicle?

Seth

 

[Cheese]

Would pvc sheets feel cheap? I want lightweight, but given the investment I am making I want it to look really good... I'll check them out when I go to HomeDepot.

I designed semiconductor manufacturing equipment for over 30 years. 95% of the equipment I designed was constructed from PVC sheet, HDPE sheet or 316 stainless.

PVC sheet 1/2" thick IS NOT LIGHTWEIGHT...a 4 x 8 plywood sheet runs about 50# while the same PVC sheet runs about 115#. What you get with PVC is chemical resistance and total water immunity.

I wouldn't characterize the look of PVC as cheap but rather sterile, as in hospital/cleanroom like. However, if you order the PVC with a hair cell finish, the slight texture makes the appearance much more appealing.

The PVC can be joined by solvent welding, hot air welding or threaded fasteners, metal or plastic.

 

[afish]

the pvc that hd sells is not the solid heavy pvc cheese is talking about. its more of a foam type pvc like its been aerated with a smooth outer skin.  Not exactly sure how to describe it but its no where near 100# per sheet. also I would not use for shelving the stuff sags. I have used the 3/4 variety and it is not nearly as sturdy as ply.  You can build a cabinet out of it however.

 

[Dusty.House]

Just thought I'd share this - it's a future expedition vehicle which a buddy of mine has just bought from a specialist ex-military vehicle company in the Czech Republic. ([member=61254]mino[/member] - Mortar Investments in Prague). It's an ex-Russian Army Ural 4320, fitted with a Kung quad-insulated box body formerly housing radio equipment. All of the stuff at the front of the box is a state-of-the-art air filtration system, plus a night heating system which runs on diesel. The truck is full-time 6WD with diff and cross locks, and it has a central tyre inflation system for sand and deep mud. Power comes from a 10.8-litre V8 diesel which does around 6 miles to the gallon and makes the most unbelievably beautiful sound. The truck was designed to be bombproof in service whilst being abused by Russian conscripts in all former Soviet zones from the Ural desert (120F in the summer) to places like Yakutsk in Siberia (-70F in the winter). It has a system on the engine and tanks which pre-heats the oil, fuel and other fluids so the engine will start first time even in those conditions. It's built like a battleship - no electronics whatsoever, everything's run using mechanical linkages, cables and big chunks of steel for easy repair in the field. The picture doesn't really do the size of it justice - it's HUGE. He let me have a drive of it round the yard of his farm - it was like driving a small town on wheels  [big grin]

They have another one for sale (only 1,800km on the clock !!) if anyone feels like a retirement adventure ......https://mortarinvestments.eu/catalog/onStock/ural-4320-diesel-shelter-1800-km

Good luck with your project !!

[attachimg=1]

I’m using something similar, a British military T244. It’s 31-years old, electric only for lights with a Cummins 5.9L.

That was 2-years ago, now it’s in a lot of finished pieces and some assembly is required

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[Dusty.House]

I thought he was talking about a Ford.

Yeah, this is definitely not a Ford. I posted photos above.

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[Dusty.House]

Have a look through this search link using 20 series extrusion. If I used this all fasteners would have Loctite on them for the final assembly, corrugations on dirt roads will shake anything to bits if precautions are not taken.
http://www.youtube.com/results?search_query=20+series+extrusion+cabinets

I’m using 80/20 for some of the structural pieces, like the bunk bed and master bed. But for cabinets it takes up too much space.

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[Dane]

Couple thoughts- google “ultralight plywood”. There are some really good and structurally sound lightweight plywood options.  Also- go to orange aluminum's website.  There are lots of aluminum options that aren’t as beefy as the extrusions with the t-slot.  80/20s Ready Frame line is similar to what orange aluminum sells. Orange also sells parts to build road cases that are used in film and music travel. Very lightweight and sturdy.