Gaucho Plywood Thickness

[Dingo Girl]

I'm replacing the plywood that the cushion sits on for the front gaucho in my 67 caravel.
What was the original thickness? The piece with the two little legs that pulls out is 3/8 but the piece that sits on top of that with the cutout to get to the pump is 1/4. Is this correct? Or should they both be 3/8?
I'm not sure that the top thinner piece was not replaced at some point. Since the pull out "sofa" across from the galley is 3/8 also.
Any help is much appreciated.

[StPierre]

On our 65 Safari it is 1/4 inch

[Dingo Girl]

1/4 for all pieces? Or 1/4 for the top gaucho piece?
Thank you!

[Lumatic]

In my 71 and 73 1/4" luan. 1/4" baltic birch would be a nice upgrade.

[Dingo Girl]

The only Birch I can get locally has MDF in the middle with Birch veneer both sides. MDF may not be the right initials.
Flat plywood seems to be nearly unobtainium these days. The big box stores get it in wet and it curls like a Pringle.

[65CV]

Your original question was "I'm replacing the plywood that the cushion sits on for the front gaucho in my 67 caravel. What was the original thickness?"

That wasn't 1/4" on our '65... it was 1/2". Unless you're really light, I'm not sure 1/4" would work.

[Dingo Girl]

I thought 1/4 seemed to be too light weight.
I think I'll try to find 3/8. It seems very solid in the "sofa".
Like I said originally I think the top piece had been re- made at some point before I got it.
Thank you for all of the input. These forums are the best!

[ttbikes]

Mine is 1/4 and I am sure it is original.

[BIGED52]

Originally Posted by Dingo Girl

I thought 1/4 seemed to be too light weight.
I think I'll try to find 3/8. It seems very solid in the "sofa".
Like I said originally I think the top piece had been re- made at some point before I got it.
Thank you for all of the input. These forums are the best!

Dingo Girl, The parts that slide out to extend these bases on my trailer are 3/8" plywood. The rear cover plywood is 1/4" for both to allow access below. If thicker upper rear plywood is used it may cause an issue/bind sliding out to bed width. Hope this helps,Ed

[prairieschooner]

Our 1958 Traveler is all 1/4" over Pine/Douglas Fir Framework. Remember they were trying to keep everything light so don't get crazy over-building but I still suggest keeping things as close to original as possible. I am not a lightweight and no problem with the original scantlings.
If you are using Birch then find a supplier that can offer a higher grade. I used Baltic Birch from Russia, very high quality and no warpage when purchase providing they stacked it properly.
If you are having trouble finding good quality try a high end cabinet shop.

[Dingo Girl]

I'm going to try to keep it as close to original as I can. I don't want to add weight if I can help it. (me or the camper )
Will go to a local lumber yard today & see what they have.

[Dingo Girl]

Who knew that finding plywood that wasn't warped would be so difficult. I'm in a rural area so sadly not many choices.

[BIGED52]

Looks like you need to make a trip to a larger city to the Big Box DIY stores! Cadillac is not that far from other areas. I would call ahead first to see what they stock. Places like lumber yards just don't carry better quality stock like they used to thanks to places like Home Depot, Menards and Lowes. They cannot compete with those DIY stores for they buy by the rail car not by the stack/pallet. Hope you can find it close to you but you may need to kiss a lot of frogs before you find your plywood prince! Ed

[prairieschooner]

Be cautious! the Birch Plywood that I got from Lowes was JUNK! did I say JUNK? wound up using it for kindling.
I went to a specialized Lumber Yard and found that they had 4 grades of Birch Plywood. The stuff that I bought is multiple thin layers of Baltic Birch and imported from Russia....guess what kind of glue? not sure but not legal in USA!
best of luck

[David F]

What about using 1/4" Masonite? Would be flat and probably strong enough. I am at the same spot in the renovation/restoration of my '67 Caravel. I am building the Gaucho different than stock so they operate better. Check out how Hoffman Architecture does it...that is what I am doing using Hafela slides. Anyway, my plan is 1/2" (5 ply) for the slide out and 1/4" Masonite or equivalent for the top fixed piece.

Incidentally, I could care less about adding weight to a 17' trailer as I am not going to add so much weight as to make it hard to tow. The 30cm granite countertop I added in the bathroom sure does not help! But, the stainless countertop in the Galley won't be too bad. And, I deleted the Galley overhead storage as well as the oven.

Dingo Girl: Let's see some photos!

[ALUMINUMINUM]

I'd guess that Grand Rapids, one time furniture capital, would have a reasonable supply of wood.

If not, despite having two Lowes, a Home Depot and a Menards in Ann Arbor, my go-to lumber supplier is in the "old School, railroad centric" downtown lumber yard called Fingerle. There are dozens of huge barns of wood. It's like an amusement park for me.

The lifer lumbermen staff behind the counter love a challenge, and try to solve any issue. I used their "better than Baltic" (on page eleven) 1/2" birch in my GT, and I'll say it's as flat and rigid as 1/4" plate steel. I love working with it. They have an extensive selection from the same cheap stuff at Lowes, to woods you never knew existed. Look through their Online Products I think they sell maple plywood cut to size by the Sf.

Here's a link to their catalog download.

http://www.fingerlelumber.com/fingerle-lumber-catalog

If you call them, explain your quandary, you might be refereed to someplace near you that can help.

[BIGED52]

Originally Posted by prairieschooner

Be cautious! the Birch Plywood that I got from Lowes was JUNK! did I say JUNK? wound up using it for kindling.
I went to a specialized Lumber Yard and found that they had 4 grades of Birch Plywood. The stuff that I bought is multiple thin layers of Baltic Birch and imported from Russia....guess what kind of glue? not sure but not legal in USA!
best of luck

Be aware of off gassing issues with items made outside of the U.S. As well as cancer causing chemicals. Just Sayin' a word to the wise. Ed

[Dingo Girl]

I found some Birch at LL Johnson in Charlotte Michigan. Honestly I never thought about the off gassing. I will call them back tomorrow & see if they have a safety data sheet on the one I'm interested in.
As far as pictures go right now it's just a tiny empty room with a new subfloor. Can't start putting it back together til the flooring goes in. They said they'd like it to be 70 degrees before they install it.
Right now I'm doing what I can so when the floor covering is installed I can, hopefully put it back together relatively quickly.
It's snowing tonight up here so I'm not sure when we will hit 65-70 degrees. May? June?
Thank you for all the responses on this thread. Very helpful.

[Lumatic]

Originally Posted by Dingo Girl

I found some Birch at LL Johnson in Charlotte Michigan. Honestly I never thought about the off gassing. I will call them back tomorrow & see if they have a safety data sheet on the one I'm interested in.

Unless one has a supersensitivity to chemicals I would not worry about the off gassing from one piece of ply. The chemical usually in question is formaldehyde. Over a few months off gassing drops off anyway.

By the way, formaldehyde is kind of ubiquitous. Hard to get away from it especially if you like a nice foamy head on your beer.

[Lumatic]

Originally Posted by David F

I am building the Gaucho different than stock so they operate better. Check out how Hoffman Architecture does it...that is what I am doing using Hafela slides.

David, I would be interested in how your slides work out and how much they cost.

Incidentally, my 71 still has the original 1/4 luan ply on the gauchos. The original gaucho design is cumbersome but simple and 45 years ain't bad. IMHO a thicker ply would also make the sleeping platform stiffer.