How do you make a sofa that converts into a bed?

Simply put you make a box and give it a lid that telescopes to double its size.

OK! But how do you do that?

Well since a picture is worth a thousand words, here's 3000.

This is one half of the lid. It is in two halves to reduce the weight that will have to be lifted when accessing the storeage underneath.

The reason for the gap in the middle is that I've used up my supply of timber so I shopping trip is needed to finish this and to make its twin.

When completed the bed will be 2m x 1.4m, big enough even for me!

I could have been riding my bike...

Yesterday got rained off but today was lovely. The bike group was on a run and the temptation to get the gear on and go for a ride was very strong. If I'd got some work done yesterday I'd probably have succumbed . However conscience got the better of me and out came the power tools.

The second section of the sofa bed is now done. I propped the sections up so that you can see how they will go together.

That's not all...

Just in case you thought that was all I'd achieved last weekend here is the evidence that I'd also trimmed back the foam and fitted the wall panel over the window and made a ply box to surround the offside wheel arch.

The channel running up the middle of the van is where the cables for the lighting will run. A removable cover will be added later.

I got the power! (credit: Snap 1990)

After several hours of chipping away at bits of wood I've discovered that I don't have the requisite skills with hammer and chisel to form even the simplest of timber joints. Having never had woodwork classes at school (or since) this should not have come as any surprise, however as I had a book and the arrogance of the uninitiated it was a bit of an eye opener.

Fortunately being a gadget nut I have accumulated an impressive array of power tools, so having admitted to myself that I am no master craftsman I delved into the dark recesses of the garage and liberated the router from the "I'll find a use for that, one day" shelf. Well that day had arrived and although initial caution was exercised (this is a scary machine) I was soon removing wood with sufficient precision to make some very tidy joints. All the while this sound track was playing in my head

This is the fruit of my labour, the first section of sofa-bed.

Ever discovered something was harder to do than you thought?

Well I just have.

Having cut the wall panel that will go over the window (which required lots of "offering up" and trimming of the profile) I needed to insulate around the window. I could have used my hi-tech blanket but it would have to be cut into small pieces, so instead I decided on expanding PU foam in a can... because I thought it would be quick and easy!

How wrong was I?

The instructions explained that the foam is cured by moisture so the surface should be prepared by being made clean, grease free and moisturised! And this is where the problems began. The surface is inclined gloss paint which I'd damped down with a water spray and I was trying to get a liquid to stay where it was put.... platting fog might have been easier!


The only thing that seemed to work was applying small blobs, leaving them to cure and then coming back to add blobs between the cured blobs. The whole process took nearly a full day and looks like something from a horror movie.

On the upside, following some trimming, the wall board can now finished which means that I can now start on the furniture.

Bl**dy Gas Alliance

So leaving me without gas and therefore no heating, hot water or ability to cook for two days wasn't bad enough for the Gas Alliance, they have also left a hole at the end of my drive which means that I've been unable to get the van back onto the drive. This means no progress this week.

Bl**dy weather!

Up before the sun today, planning to get lots done, unfortunately the weather gods had different plans.

You've been framed!

Saturday we had another shopping trip this time for some vinyl floor covering and some (rather wacky) fabric for the sofa/bed. As a result we didn't get lots done but we did finish wall board in the rear of the van and the frame for the window, which was challenging as it has to taper to follow the contours of the van.

But worth it

This is the first wall lined with the wall board. There will be some trim added later to cover the joins and screw heads but so far I think it looks pretty good.

The wobbly nature of the board means that it easily follows the curvature of the van.

Damn this is tricky!

The wall board is 3mm ply with a vinyl facing, it comes in 8'x4' sheets and boy is it wobbly. Cutting these sheets to size and leaving a clean edge is NOT EASY!

Floor done, now for the walls

This insulation has five layers of aluminium foil so not only should we be realy toasty but we'll also be immune from those alien mind probes.

It's all in the hip action

When drilling it's important to have a firm grip and apply steady pressure.

It goes down easy too

The time consuming part is sealing all the cut edges with aluminium tape. It's super sticky and surprisingly delicate.

It creates an effective barrier to moisture and drafts in addition to being a superb insulator.

I like tech

and this insulation is seriously techy.

Self mutilation

No DIY project is complete without shedding some blood.

The lesson here is to exercise caution when handling the piece of steel that you have just cut out to fit the window. The other lesson is that phone cameras don't always focus on the thing you want them to.

Timber and glue

The batons have been glued to the floor with Sikaflex 512 and will be left overnight to allow it to cure.

From this angle you can see the timber frame that acts as a spacer for the window, also glued with Sikaflex.

Fit window, drink tea

OMG! I just cut a great big hole in my van!

So why am I smiling?

In this shot you can see my Keith (also smiling) in the vans interior. As any good workman knows it is essential to look after your tools. This particular tool is looked after by lubricating with a steady stream of coffee.

Then you join the dots... with a jigsaw

Note the duct tape to prevent scratching the paintwork.

The sawing is made easier by using a very fine toothed blade and by having a Keith, who stands on the inside and damps down the vibrations.

Next drill holes in the corners

Some people drill a small hole in the corners (just enough to get the saw blade through).

I decided to drill holes with the same radius as the corner of the window that will fit through it.