1 · Measure the actual van
The galley target is 36 L × 18 D × 32 H in. Keep its base, fridge venting, and fastening clear of the sofa-bed motor, wiring, switch, and full travel. Final length = smaller of 36 in or (D − 2 in). Final depth = smaller of 18 in or (B − 24 in aisle target). Keep a 1 in fit allowance at each wall/trim end and size the cabinet only after a cardboard mock-up.
Enter B and D to calculate a preliminary cabinet limit.
2 · Parts and rough cut list
| Part | Target | Final cut rule |
|---|
| Galley cabinet carcass | 36 L × 18 D × 30 H | Cut from actual available run and wall template; top adds ~2 in |
| Countertop | +1 in overhang front and ends | Template the wall curve before cutting |
| Fridge bay or open shelf | Per selected fridge | Use fridge maker's clearances and vent path |
| Water container cradle | One 5–7 gal removable jug | Size to jug; strap down near floor |
| Bed topper | Foldable, ~3–4 in thick | Cut only after powered sofa flat size and travel are verified |
| Removable table | ~28 × 18 in | Place only if rear door access and sofa travel remain clear |
3 · Fit gates before construction
- Run the powered sofa through a full seat-to-bed-to-seat cycle. Measure the flat sleeping surface and travel envelope; locate the switch, motor, wiring, fuse, and manual release if equipped.
- Remove only the middle seats you choose to remove; retain the powered rear sofa and all its controls. Photograph and retain original hardware; do not cut seat-belt anchor points or structural floor members.
- Make a full-size cardboard galley mock-up. Move both front seats through their full travel, operate both side doors, cycle the powered sofa, and walk the aisle.
- Check for roof/window leaks and floor rust under the carpet before hiding them with cabinetry.
- Read GVWR and axle ratings from this van's door label. Weigh the van with fuel, occupants, and planned equipment before assigning a build weight budget.
4 · Installation sequence
- Clean and repair leaks or rust; verify the mechanic's purchase inspection findings. Test the original TV/VHS wiring, both radio/cassette units, rear light strip, and sofa-bed circuit before changing equipment.
- Measure and mark floor positions; use tape and cardboard for a one-night trial layout.
- Template cabinet base and wall curve. Build lightweight plywood cabinet with rounded edges and positively latched doors/drawers.
- Fasten cabinet to verified structural mounting points with appropriate reinforcement. Do not rely on carpet, thin trim, or wood screws into the floor alone.
- Secure fridge and water jug inside the galley, and the power station separately, against movement. Keep water connections accessible and separated from electrical gear.
- Reuse the overhead cabinet if the replacement TV fits and can be mounted securely. Secure the DVD player; verify compatible TV input, power, ventilation, and cable access. Keep both radio/cassette units and rear light strip. Add new circuits separately; reweigh when complete.
5 · Equipment arrangement
| Zone | Placement / reason |
|---|
| Sleep / lounge | Existing powered sofa bed; leave motor, switch, wiring, and full travel accessible |
| Cook / prep | Driver-side counter; portable stove used with required ventilation, stored when driving |
| Cold storage | Under-counter fridge or portable cooler with maker-required ventilation |
| Water | Removable jug low in driver-side cabinet; simple basin optional |
| Power | Secured portable power station low, dry, and accessible |
Hold point: This is ready for measuring and mock-up. It is not a cut-ready set of van-specific dimensions until fields A–H are measured, the powered sofa travels freely, and doors, seats, circuits, and axle weights are checked.