With our Thermal Pack built and tested (write-up here; http://www.wanderthe...mal-pack/page-2 ) we seem to be about 95% done with all we had planned to do.
We started with this setup;
2004 dbl cab Tundra with RideRite airbags
2014 Hawk shell with these options:
2 Solar plugs
Furnace and propane
Fantastic fan and extra roof vent
Rear wall steps
Additional driver's side window
Aux. battery system
Gas struts (4)
Jacks and brackets
Looked like this inside;
Knowing we were going to build a front dinette, we didn't want the wall cabinet to be in the way of getting in and out of the passsenger side seat. I pulled it off and cut it down and remounted it.
I had to create a table for the dinette and I wanted it to match the counter top over the heater. I had enough Formica laying around to do the job so I unscrewed the counter top (with some difficulty as I did not want to remove the heater and it is screwed from below)and removed it. While I had it off I installed a voltmeter (detailed here; http://www.wanderthe...hole-voltmeter/ ). Then I built a slightly larger top and installed it.
Next I added the seat buildout out of 1/2" birch plywood with maple rails.
I had to cut down the long narrow door over the stock storage area in order to accommodate the new larger door created by the seat buildout.
Here is the door closed,creating the seat.
We bought a sheet of 4" decent quality foam online from the Foam Factory and ordered fabric to match our existing upholstery from FWC. We cut the foam to fit our needs and hired a local woman to sew it all up for us. I made plywood backs to go behind the seatback cushions and extended the upper bed slide out rails for them to lean against. I bought a different thermostat at Amazon (http://www.amazon.co...2190_TE_3p_dp_1) as the one that came on the Hawk came with a setpoint that was too high for our needs.
It had to be moved up a little to accommodate the rail extension.
So here is the finished product:
Seatback with a bolster behind creates the proper seating angle, at least for us. I used our dining room chairs as a template of sorts.
The result is a seat that is comfortable for sitting at the table,
or it can be turned the other way for lounging for her on the driver side,
or me on the passenger side.
I raised the floor between the seats so our legs wouldn't dangle while sitting and created some storage underneath.
NorCalHawk was kind enough to send me the table supports he was no longer using so building the table top was straightforward. I used formica on the underside of both the table and countertop, the former for strength and the latter because that's the way FWC does it (I assume for heat protection in the heater area?).
The dinette makes into a comfortable bed for one person.
And finally, we had a receiver hitch step made by a local welder.
The foam and reflectors are ours. Had to move the license plate up a few inches to make it visible.
Costs, roughly, so far:
Misc. hardware $ 65
FWC fabric (&vinyl) $206
Thermal pack mat. $215
Misc other $ 25
Thermostat $ 50
Rough total $676
So, there it is. Many thanks to all the contributors that gave us so many great ideas.
See you out on the road!
R and K