Scratching the Surface, while Making the Surface Unscratchable (A Pop-Up Update)

Author’s note: I am a little behind on these posts, but for once it is not for a lack of writing . . . the Central Valley in California has been dealing with a massive fog cloud that has not moved for weeks now. As a result, the temperature has barely risen above 50 since before Thanksgiving, which means that I cannot do a lot of the stuff I need to do right now outside. So, I only have one “final product” picture (see the banner image above) . . . you will just have to imagine the rest!

There’s “dated,” and then there’s “atrocious.” Somehow, our camper’s countertops and table managed to be both. I was approximately twelve when our Coleman Cape Cod pop-up camper was built (a sobering thought when I consider how “old” it is), so I was both alive and conscious of my surroundings when someone made the aesthetic judgment call to give its particle board surfaces a splotchy blue laminate top. And you know what? I don’t remember my parents or any of my friends’ families owning anything with that color scheme. Sure, I recall there being lots of wood paneling, and a fair number of those old suede davenports with pictures of wagons on them, and thick drapes seasoned over the years with plumes of cigarette smoke, and wooly carpets stockpiling decades of food crumbs and dead skin cells and animal hair, and giant console televisions with either a Nintendo or a Sega Genesis (NEVER both, at least where I lived) perched on top . . . but nothing, anywhere, with that weird shade of blue.

As much as I favor historic preservation, these countertops had to go.

So this begged the question: what should we replace them with?

Well, maybe it is the academic in me, but as with many other questions that prompt a single answer came up with three instead.

Benchtops: Red Oak, Green Moss, and a Hidden Gray

The red oak was just standing there, doing nothing except getting wet.

I bought several rough red oak boards a couple months ago for use on a different project. Shortly thereafter, we bought the pop-up, and I tabled the other projects for the time being. But as I’ve mentioned in other posts, we had our first winter storm of the season just a couple of days after taking possession of the camper. Like Gremlins and the Wicked Witch of the West, unfinished wood does not hold up very well in the rain, so within a few days I saw some moss and mildew beginning to ascend the planks like kudzu.

It would be a shame to let good (i.e., expensive) wood go to waste, so I improvised a solution: I would make some new benchtops and cabinets for the pop-up. After planing several boards down to about half an inch thickness, I trimmed their edges and cut them down to the width of the original particle wood benchtops. Then I joined them together with pocket screws and wood glue. I also added a 3 1/4″ inch diameter hole to one of the pieces for a grommet I am going to add later.

The tricky part was the finish. I bought some Flagstone-colored Teak Oil + Stain at Home Depot, and because my brain works differently than most I looked at the color pictured on the can instead of visualizing the color it named. You can see the difference pretty clearly on the product’s Amazon page:

This stain’s Amazon page shows that the color shown on the can is not the same as the color inside.

Anyway, suffice it to say, after thoroughly sanding the wood and applying some conditioner to facilitate the finishing process, I was curious why the stain itself seemed so . . . gray. JoAnna and I had agreed on a darker stain for the counter/bench-tops, like walnut or nutmeg. After a lot of superfluous stirring, two applications, and a couple days cure time, however, the final product still looked pale, as if the boards had seen the Ghost of Christmas Camper Past.

In the end, I mitigated this error somewhat by dousing the pieces a couple of times with a more appropriately-colored Danish oil. It did not completely offset the gray streaks, but the wood has taken on a redder tint. Now that the lacquer top coat is on and the pieces have a slight gleam to them, they basically pass for what we had envisioned all along.

The Dinette Table: Creating a Pop-Up Diner in an Actual Pop-Up

I don’t know what the term is for a non-sexual fetish (I’m sure the Germans have a word for it . . .), but that’s how I would describe my affinity for diners. I don’t necessarily mean the food—I fix a better breakfast than the average short order cook, and most evenings I would prefer Phở over a patty melt—but I’ve loved the diner aesthetic for as long as I remember. It may be the memories I have of going to the Scott City, Missouri Huddle House in the middle of the night with friends back in college; or the occasional date at the Omega Cafe in South Milwaukee; or going to Cafe 50s in West Los Angeles the morning of my PhD comprehensive exam and taking my stress out on an omelet. Whatever it is, I adore diners, and I seldom pass up an opportunity to grab supper at our local Mel’s.

An old picture of an old Steak N’ Shake on the company’s new website.

I did not explicitly have diners in mind when I began designing our breakfast nook remodel, but they quickly began to dominate my design choices. I used some oak from JoAnna’s father’s ranch that I had laying around for a few years in our old garage to make a wrap-around bench, and our walls are covered from floor to ceiling with diner pastiche. I even put up some black and white photos of an old Steak n’ Shake crew that I found online. If I ever get my hands on an old high school volleyball calendar or a front page picture of a prize horse bound for the Kentucky Derby in some local newspaper, you can bet I will find some space for it.

I was more explicit this time around in channeling the diner motif. Our pop-up’s dining booth is really just a not-so-glorified folding table. Of course, it had the same dull blue laminate as the other countertops, so it matched its equally hideous neighbors. Rather than replacing the table itself or even the top, I decided to paint it and then give it a shiny epoxy glaze. I also wanted some kind of scalloped metal trim around the sides.

The latter item on the wishlist took the least amount of time to fix, but the most time to research. Most commercially-available scalloped metal edge trims are 1.25″ high or taller, and the t-shaped molds placed the back piece about three quarters of an inch down from the top. The problem was that this table’s surface was only about a half inch thick. This meant that I had to make my own, which led to another problem: I don’t have the equipment or the skillset to scallop a metal edge band. I asked a few friends of mine if they had bead rollers I could use, and at one point I even thought of using a can opener to run a few lines down the middle of the 20mm wide adhesive metal edge banding I ordered on Amazon. In the end, though, I decided on a simpler solution: I ordered another roll of adhesive metal edge banding. This one was only 15mm wide, so I carefully glued it onto the wider one as I unrolled it. It’s not what I originally had in mind, but the two bands stacked together give the combined piece enough vertical relief that it at least appears scalloped. And I didn’t even have to buy a bead roller, so . . . score!

The Omega Restaurant in Milwaukee, Wisconsin is one of many fantastic diners in the area. It may also be my all-time favorite in terms of the food . . .

If the metal edge band took a lot of cognitive time relative to what I needed to actually assemble it, the paint and epoxy top coat process was the opposite. The painting part was breezy and fun. After scuffing the surface with 220 grit sandpaper, I applied a spray coat of white primer. I then gave it a colonial red base coat, followed by several rounds of dusting the surface with yellow, orange, and candy apple red spray paint (I’m fairly certain the clerk at the hardware store who sold me the paint thought that I was some kind of middle-aged graffiti artist). Once the table was dry, I laid down two full coats of glossy sealant and painted the legs marbled black with some Rust-oleum. I also had Clementine help me spread a little flakes of glitter on the top so that we could make it sparkle in the light. However, once we moved on to the epoxy (which only took half an hour to mix and apply), we were hindered by one factor we could not control: the weather.

Epoxy resin cures best in temperatures between 60 and 80 degrees Fahrenheit. Last week I poured the epoxy and blasted the table with a heat gun for about twenty minutes, which helped the resin set while allowing the bubbles to escape. Later that night, though, the temperature dropped down to almost freezing. When I went outside the following morning to check on it, I could tell the epoxy was still wet to the touch.

With rain on the way and no end to the cold snap in sight, I gingerly picked up the table like a caterer carrying a tray full of champagne flutes, and moved it into my heated workshop. It finally started to cure, but there are still a lot of little tiny bubbles throughout the glaze. I’m going back and forth on whether it is worth sanding it down and applying a top coat, but for the time being I’ve got bigger fish to fry.

Butchering the Butcher’s Block

The last non-sitting or sleeping surface in the pop-up (besides the floor) was the kitchen counter. As with the other countertops, it was a pale blue. Although the previous owners did a fantastic job cleaning it, the color was less than appetizing. I did not want to cook on this surface as-is.

Early on in the process, I wanted to build and install a butcher block countertop. I’ve always wanted to make butcher block, and like most backyard woodworkers I had plenty of scraps laying around. Butcher block gives one an excuse to hoard all of the long, stray cut-offs that come from ripping pieces of wood on a table saw. A one inch wide by twelve foot long oak furring strip does not hold a lot of promise for most projects, but it is perfect for butcher block.

The formula for butcher block is simple: take lots of wood strips, lots of wood glue, lots of clamps, and then squeeze them all together into a sticky, pressurized sandwich. In practice, though, it is a bit more complicated. For instance, every wooden line needs to have a uniform width from one end to the other, so if you have a strip of wood that has a narrow bit then you’re going to have to plane the rest of the board down to that lowest common denominator. Also, there are a few aesthetic principles to consider when arranging the wood. Although there is no rule against alternating wood species within a single horizontal line, it might look a little weird to have a lighter and a darker tone along the same horizontal axis on either side of a sink. It is also prudent to alternate tones across the vertical axis, or to at least make them cohere together somehow in a way that seems more planned than haphazard.

In any case, I am always happy to complete a project with wood I already own. Last year, I bought and assembled a small wooden storage locker for my bike. The package arrived on a palette, and its individual components were stacked on top of one another with long, thick, square-shaped pine dowels. Since I refuse to throw wood away, the dowels have been leaning against our house like medieval pikes ever since. Fortunately, this project gave me an opportunity to finally use them for something. I also had several long strips of walnut and mahogany from a previous build, which offered a color contrast to the pine.

However, once I chopped everything up and clamped all the pieces down, I started to realize how difficult it is to create butcher block with a 11″ inch throated planer, especially when I had to dimension them down at least 50% in terms of their thickness. This resulted in a lot of passes through the planer (some were rougher than others) and a lot of juggling to make sure that they all ended up having the same thickness.

Anyway, it’s still cold outside, so the glue-up is moving at a glacial pace. It’s mostly done right now, but it looks more like an Amish Tetris game than a countertop. With some luck, I will have some snazzy photos to show next week.

Until next time . . .

All the Stuff that’s Fit to Print (A Pop-Up Update)

Most Americans accumulate stuff over time, and far too much of that stuff ends up at yard sales or waste bins. Over the years I’ve bought my share of produce that wilted, books that sat (and continue to sit) unread, and various things from Target that found a place inside my shopping cart but not my home.

But on the opposite end of the “stuff spectrum” are those things we use continuously, whose return on investment is infinitely higher than what we originally paid for them. For me, I think of the cordless Milwaukee Impact Driver I’ve had for 8 years now and have probably used a few thousand times, and the pair of Bose over-ear headphones I used so often that the leather padding for the ears had worn down to a nub (I have recently replaced these with a new pair that features longer battery—and presumably ear pad—life). Then there is my 2022 Ford Escape PHEV, which has almost 55,000 miles on it . . . this is about the point during my usual tenure of car ownership when I start fantasizing about my next ride, but I love this vehicle so much that I was almost as relieved about it surviving getting jackknifed on the freeway over the summer as I was about surviving myself (though I’m sure my family would disagree).

The newest entry to this list is my FlashForge Adventurer 5M 3D printer. I bought it almost on a lark when it was available for a deep discount on Amazon and I needed to create some custom wiring panels for my workshop, but during the past several weeks I’ve already burned through over a half dozen rolls of filament. I have since become comfortable enough on TinkerCad to cobble together a new design whenever I want to make something new (which is often). But while I am already lamenting the absence of features one finds in higher-end 3D printers, the Adventurer 5M does the fundamentals well enough that I am in no rush to upgrade it.

I’m able to make all kinds of things on my new 3D printer, including this combined salt and pepper shaker set/spice and olive oil holder that fits our tiny pop-up kitchen counter.

Although I have made a lot of things (including many failed prototypes) over the past couple of months, the main inspiration for my 3D printing thus far has been the pop-up camper. Or, specifically, a small but invaluable piece of it: the cabinet drawers.

Reinventing the Wheel (or just the stuff at The Container Store)

When we first opened the camper ourselves, we did not have a lot of time to poke around. The sun was setting, a winter storm was on its way, and we were nowhere near ready to fix the bed. Almost as soon as we ripped the queen-size bed out of its cocoon, we had to jam it back in. Before we closed it up, though, I pulled out three drawers (including two from the kitchen) and removed them from the camper.

Weeks later, the drawers are still sitting in our house. However, each one contains a lot of organizational scaffolding and a wide variety of 3D printed sub-containers.

Terrace farming is an elegant example of vertical space being used efficiently. Fukuoka-Tsuzuru Rice Fields in Japan. Wikicommons. Author: うきは市

My main priorities for the drawers were to clean them out, to squeeze as many different things as possible into each one while making them user-friendly, and to try to prevent those things from jostling around too much during transport. I took care of the first priority on day one with some cleaning wipes and a roll of shelf liner from the dollar store. But the other two goals have consumed much more time, as well as dozens of hours of printing and a few rolls of PLA filament.

Fitting as much as possible into a drawer is simple enough. Just ask our kitchen junk drawer, which has so many things stuffed into it that roughly half the time I try to close it, I need to shift a few things around so that it can clear the cabinet lip. I did not want to take this haphazard approach to the camper, however—I spend enough of my ADHD existence looking for things at home to want to waste my time doing this while on vacation. So, everything we store in it needs to have a home.

Moreover, we want our camper to be as “plug and play” (to use a computing term) as possible. If it’s 3pm on a Friday afternoon and we feel like taking an impromptu trip, we don’t want to spend the rest of the day tracking down supplies and gear, only for us to roll into our space long after Clementine’s bedtime. We want to be able to pack some clothes, buy some food, hitch the wagons, and then hit the road. Therefore, I want to be able to store as many things that we need as possible so that we won’t have to remember them. Any item that is already in the camper is an item we won’t have to remember to bring.

The key to this, so far as I could tell, was vertical space. Whenever we look at a drawer, we visualize it first in terms of horizontal space, and then in terms of whether or not something will fit vertically. For our camper drawers, I wanted to stack things we use more frequently on top of things we don’t (but still need).

I also wanted to maximize horizontal space by making bespoke partitions for our various things. For instance, rather than scouring IKEA and Daiso for utensil holders that would fit our spoons and forks with room to spare, I wanted to print my own. Our eating utensils each have their own little boxes, which are large enough to make retrieving one easy but economical enough to free up a little additional space. These little pockets of space soon added up to make bigger spaces for additional things. I also wanted to store some things horizontally that would usually be stored vertically, such as wooden spoons and chef’s knives. This required framing those things out in such a way that they would “stack” together horizontally without scattering after the camper hits its first pothole.

After several weeks of trial and error, experimentation, and looking way too “intently” (my wife’s word) at a kitchen drawer for concerning lengths of time, I’ve finished Camper Kitchen Drawer 1.0. Below is a photo:

Our pop-up kitchen drawer. I still have to reprint a couple of things (particularly the spoon/knife/tongs holder), but it’s about 95% done. Note the green handle, which can be used to lift the silverware tray.

Starting on the top left corner and moving counter-clockwise, I have a wooden box from Daiso that has become a miniature cooking utensils drawer. It holds a variety of tools, from bag clips and a lighter to a small whisk and tongs. This box takes up most of the vertical space of the drawer, so nothing is stored underneath. Next, though, you will find a three-tiered stack: a bespoke eating utensils organizer, a tray containing a small cutting board (with included paring knife) and scissors, and the camper manual. To access the cutting board and scissors, one can pick up the utensils organizer using the retractable green handle (which uses barrel hinges to swing it from its storage position inside the spoons tray to its closed position as a handle). If we need the owner’s manual for some reason, we can also remove the cutting board tray. .

On the right side of the drawer I have a flashlight, a variety of wooden spoons and spatulas, a large set of tongs, and a chef’s knife. I also made some space for candles, dish soap, and water bottle cleaner tabs. The spoons are held together with a grooved stand and a slotted bar for the handles, while the tongs and knife have large receiver boxes at either tip. Note the latest addition on the right: a wooden spoon container with a magnetic back that can be mounted onto the side of the kitchen cabinet (which will have a large magnetic strip attached). You doubtlessly noticed the banner picture for this post, which is what this looks like on the other side . .

As for the other two drawers, I took a similar (if slightly less elaborate) approach. Our narrow kitchen drawer contains Keurig coffee pods, tea bags (with three separate bays to allow for different varieties), small red tins for spices, a salt and pepper shaker set, etc. Meanwhile, the other drawer has been reserved for reference, electronic, camping, and personal care products. I also included a travel journal (appropriately named “Van Life”), a pop-up camper travelogue and “how-to” book, and a set of colored pencils and markers in case any of us want to draw something.

You can download the .stl file for my “Red Tin Box Row” here: https://www.tinkercad.com/things/dljqw3D3TKD-red-tin-box-row

And here’s the link for my Spice Row (including Salt and Pepper Shaker Set): https://www.tinkercad.com/things/gzpzYWrLugl-food-drawer-condiment-and-spice-row

Our coffee/tea/spice/soap/miscellaneous drawer. The Altoids slots in the back are for daily medications, and underneath there is additional storage for whatever else we want to put there. Note the container to the left of the “Sugar” tin, which is actually a spice wheel.

A Work in Progress

I hope that this combination of organized stacking and customized fittings will survive the road as well as the rigors of our family using everything and then remembering to put everything back when the trip is through. Although this has yet to be battle-tested, I am happy with how this turned out and look forward to using it on our inaugural trip.

Nonetheless, I was both surprised and mortified by the amount of time I invested into designing and laying out these three drawers. Even though I was excited and had virtually nothing else to do (at least with respect to the camper) for the first week, it certainly did not portend an expedited timeline for the rest of the project.

More problematic in the long term, though, is this system’s inevitable impermanence. As we start to get our camper “sea legs” and figure out what we use and what we don’t, plus those things we need often and did not think to buy early on, I will no doubt have to change this system and print a bunch of new things. And I will be honest . . . I’m not excited about that!

In any case, I think this is at the very least a great starting point, and perhaps it will give others who are starting (or dreaming) of their own pop-up camper, RV, or tiny house projects a template for their own limited storage spaces. Of course, most tiny homes do not have the space required to house a 3D printer. However, having access to one will do wonders for anyone trying to maximize limited spaces, both outside and inside their homes. As we all continue to accumulate more stuff, perhaps we can move away from purchasing bigger houses and renting out expensive storage lockers, and toward maximizing those spaces we already have. And by extension, we can focus less on acquiring stuff we don’t need and won’t use, and more on giving those items we use, value, and treasure a proper home.

“The Bones are Good . . .” (A Pop-Up Update)

My dog was peeing on a rose bush when I first saw the “For Sale” sign. After months of it being parked somewhere in their backyard, our neighbors’ 1993 Coleman Cape Cod pop-up camper now appeared in their driveway for passerby to consider purchasing. “Scruffy, check that out!” I exclaimed. “It’s a pop-up camper! I’ve always wanted one of those!” Scruffy, our adorable but not especially intelligent shih-tzu, said nothing in return before following me across the street to check out the vehicle.

The camper had seen better days, the majority of which probably took place during the Clinton administration. Although the weather sealing was intact, the paint was scuffed and faded after one too many afternoons in the California sun. The tires were old, the hitch seemed slightly out of joint, and overall the contraption resembled some kind of cruel “tenement-in-a-box” Transformer toy.

Naturally, I hurried home and told my wife how amazing it was.

A picture of our 1993 Coleman Cape Cod pop-up camper, in the open "popped up" position, looking at the starboard side. Our daughter Clementine is smiling at the camera and standing in the doorway.
Clementine standing in the doorway of our new camper.

If We Build it . . .

JoAnna and I have talked about getting some kind of camper for years. She wanted a pop-up, and I wanted to build something from scratch. This opportunity helped us meet in the middle: the camper for sale needed some TLC, but not much else.

I have always wanted to build a cabin or camper of my own . . . something that would give me a little piece of the woods to call my own, a shelter from the cold and the wind that would nonetheless allow me to look up every now and then from my research and writing and see tall, evergreen trees. As I finished my work on the Grandpa’s Letters book, I took a couple of “writing retreats” to the northern coast—first to Fort Ross a couple of years ago, and then most recently to Shelter Cove. I mostly read and wrote during those trips, but I also took a bit of time to walk along the coastal bluffs and watch the waves as they crashed down upon the rocky shore. These trips were both productive and memorable . . . and expensive. A pop-up camper would give me the flexibility to do this more often, while staying closer to home and having my own space to occupy.

Of course, I would be remiss if I did not mention the other daydream I have with this camper: exploring the West with my family and friends. Clementine is now fond of camping, but she is less fond of tents and bugs. I cannot say that I blame her on either score . . . tents can be miserable, and flying insects have a tendency to want to become best friends with my eyeballs. But a pop-up will give us some protection from these and other elements of the vast, unforgiving wilderness, while also giving us a few creature comforts of home: heating, potentially even air conditioning during the summer; electric lights and phone chargers; and a dining table without any bird crap on it. We can wear the woods like a jacket: we will put it on and take it off as needed, then we can hang it nearby for our next easy-access adventure.

My overall logic going into this was not unlike Ray Kinsella’s in Field of Dreams: if we build it, we will go. A pop-up camper can be like a small portal for people who want to teleport into the forest every so often. My hope is that we can trade the drudgery and anxiety of packing for a camping trip for a pumpkin that will turn into a pop-up carriage with just a little pixie dust (and a moderate amount of arm strength).

I don’t know for sure if it will help us “go” . . . only time (or maybe the ghost of John Muir showing up outside with a can of paint) will tell. But what I did know was this: I was ready to build it.

Caveat Emptor

That weekend, we walked over to our neighbors’ house with Clementine to take a look. It was more or less kind of what we expected, at least in terms of decor: ugly blue countertops, faded pastel curtains, and a folding table buried beneath large cushions greeted us inside. But while its looks could kill (not in a positive way), the structure itself was in good shape. There was no evidence of mold or mildew on the bed canvas, nor any rust on or underneath the structure. The pop-up mechanism unfurled the top smoothly, like some ancient booby-trap springing to life in an Indiana Jones movie. In the interest of full disclosure, the neighbors mentioned that the queen bed on one end of the camper needed to be repaired and that the refrigerator had not worked in decades. Beyond that, though, it was in pretty good shape. The owners had also made a few upgrades of their own, including new vinyl plank floors and a relatively fresh battery.

A picture of the inside back half of the pop-up camper, which contains a full sized bed, a table (which is covered by cushions), several other cushions, and a couple of countertops.
The aft end of the camper.

“Well, the bones are good,” I remember saying, as if it were a house, or a skeleton, and as if I knew just what in the hell I was talking about. “But we need to go home and think about it.”

“Sure. Take your time.”

We did not need to take much. After careful deliberation and some quadruple-checking of our driveway’s width to ensure that it could squeeze past our brick Tudor home and into our backyard, we called the next day and offered to buy it.

We were soon the proud owners of a pop-up camper.

“Now what?”

Since we bought the camper in late October, we figured it would be a few months before the coming winter subsided enough to allow for a comfortable glamping experience in the Sierras someplace. So, in theory, we would have plenty of time to fix it up.

Our plan of attack was simple in the same way that all such plans seem simple at the outset: we would fix the bed, refresh some of the furnishings, give it a decorative flourish, and take it out within a few weeks for our first trip. However, the road to hell is paved with good intentions, and without new tires I did not think the camper would last long on such a surface. We also discounted a few additional factors at the outset: my raging ADHD, my closely-related fascination with my new 3D printer, an aging and unreliable electrical system, and above all the universe of possibility that cleverly concealed itself within what appeared to be a giant pack of cigarettes. As the project gained momentum, so too did our imaginations of what we could do with it. And by “our,” of course I mostly mean mine. ⚾🧢💣

Author’s note: I wrote this myself. All errors and mistakes are mine . . . but so are all of the jokes.