How to Make a Pull-Out Campervan Bed: Peugeot Expert Camper Conversion
Welcome to the 10th instalment of our camper conversion series! In this post, we'll be building a pull-out bed for our 2020 Peugeot Expert. You'll find a step-by-step guide along with helpful tips and tricks for your own project.
Tools Used:
Aprox 17 metres of Redwood 50 x 50 mm (2" x 2") PTL NOM: Link
Aprox 26 metres of Softwood Whitewood 50 x 22mm (2" x 1") PTL NOM: Link
x3 Ply Wood 1829mmx607mm7x5.5mm :Link
Mitre Saw: Link
Twin Pocket Hole Jig: Link
63mm Self-Cutting Threaded Square Drive Screws: Link
24 Inch Clamps: Link
Drill
Angle Brackets: Link
4 latches: Link
Measuring Tape and Pencil
Step One: Planning the Dimensions
I placed some of the main components of the van, such as the leisure battery, fridge and water containers, so I could design the layout around them. Then I used tape to mark out the dimensions of the bed and cupboards.
The tape made visualising the layout much easier, and I used it to draw up a rough plan and item list. Once I had purchased the wood, I laid it out in the van before drawing up the final design.
Step Two: Cutting the Wood to Shape and Drilling Pocket Holes
I made a cutting list and prepared the wood for the bed frame. I cut the wood using a mitre saw, which saved a lot of time.
Then I used the pocket hole jig so the 63mm screws would be out of sight. It also helped to avoid screws hitting each other as I'd be joining multiple pieces in the same place. See video for directions.
Step Three: Gluing and Screwing the Frame
We applied wood glue, clamped the frame, then screwed it all together. We used two screws in each joint so there would be no movement.
Using large clamps made the process much easier.
Step Four: Installing the Slats
Once the main bed frame and two pull-out sections were built, we placed them in the van so I could measure the length of the slats more accurately. I did this because the walls of the van aren't straight, so the slats needed to be different lengths.
After cutting them all out, I drilled pilot holes and used a countersink so the screws would sit flush with the wood. This would stop the fabric seats from getting caught.
Then I clamped the first pull-out section and screwed in the slats on each end. Then the slats alternated between the bed frame and the pull-out sections.
The smallest possible regular gaps between the slats would have been just over 2cm, making 8cm gaps when the bed was pulled out. I decided to do 5 mm gaps and staggered the gaps at the end, where it wouldn't be as noticeable when we're lying down. This would make the mattress more comfortable.
Note: I designed the bed with two moving sections to make it easier to pull in and out as well as make the space more flexible.
Step Five: Making the Plywood Sides and Face
The final step was measuring and cutting the plywood faces to shape so they could fit on each side of the bed.
I had had the plywood end 5mm above the slats to hold the seats in place.
I used an 80mm hole saw to make the curved corners and cut the pieces manually by hand, as it was easier to get a straight line than with a jigsaw.
Then I drilled and countersunk the holes.
And finally, I clamped the pieces to the bedframe and screwed them in.
Step Six: Fastening and Securing the Frame
I used two L shape angle brackets to secure the bed to the floor of the van.
The last step was installing latches to hold the pull-out sections in place when the van is moving. I used four in total, two for each pull-out section. I placed one on the lower corner and one on the top opposite corner; this reduced vibrations from the road.
What's Next?
The next step in the conversion will be installing the electrics. Sign up to get notified when we post our next update, or alternatively subscribe to my YouTube channel.
Comments