Finished up the rear cabinet and then some.
It was a little tricky cutting out the door from a sheet of birch plywood with a jig saw. I understand there is a way to plunge a jig saw into plywood, but I needed accuracy. I drilled several small (maybe 3/16") holes along my cut line, and then cross drilled those to create a slot that I could put the jig saw blade down into. The result is flush door with matched grain to the outer frame that helps create the feeling of more space. I used some self closing surface mount hinges that required no large bore or holes other than for screws. We'll see how these hold up, so far so good. I also looked endlessly for a low profile pull knob or handle. I did not want a regular cabinet knob or handle that stuck out and caught the straps of backpacks and other things. Marine style slam latches required a lot of careful drilling and were expensive. I then realized the good old stainless steel Footman Loops that I use for 1" strap tie downs (like for the cooler) are also available in larger 2" sizes. Works great, cost is minimal, doesn't grab straps, and easy to install. Finally I installed the plywood section that makes up the side of the storage bin and will support the bench seat/bed.
Working with getting a nice smooth finish on this birch plywood I discovered that this wood has a sort of tiny hair that sticks up even after sanding with 220 grit. As I ran the palm of my hand one direction with the grain i can feel these tiny hairs stand up, and then going back the other direction they would lay down and make a more smooth surface. I made note of this when applying poly so that I used a one-direction brush stroke that laid these little hairs down. That's all for now, have to attend my brother's wedding so it will be a few days before I can get back to it.
Edited by BlueSky, 04 August 2018 - 01:08 AM.