Build On The Go! | EP. 3- 2008 Fleetwood Expedition – RV Solid Surface Tops & Shower
Today’s installment of our Build On the Go! series takes us back to the 2008 Fleetwood Expedition RV that came down from Sacramento for renovation.
In our first episode of Build on the Go, we talked with the customers and learned why they brought their motorhome to us at Leisure Coachworks. They talked with Jon, and with us about RV living, their motorhome, and what they want to change about the interior of their Expedition.
We then got a terrific look at the mock-up process and learned how important it is to communicate with the customers every step of the way. One of the major changes this customer wants is a bigger workspace.
Working with Jon, they chose an arrangement that offers more seating, a new cooktop, flooring, and curtains. They also decided on an expanded shower area, a new bathroom floor, and solid surface replacements for the shower, vanity, and sink.
Our second episode focused on the very beginning of this RV remodel. Jon showed us how this big Class A motorhome looked when the old elements had been removed. We got a look at some structural work, including the straightening of a wall.
We were also able to appreciate how an RV interior has to be designed using every inch of available space. Jon showed us plans to hide wires and plumbing while combining design with function.
We saw framing for some of the new elements and a new custom bathroom floor. The team was waiting on some vendors before tackling the new solid surfaces in the bathroom.
Going Beneath the Surface
Today we’ll be talking about those solid surfaces. Jon is going to walk us through how these surfaces are created and turned into beautiful components for the RV kitchen and bathroom.
The solid surface comes to Leisure Coachworks in pieces. Each piece was cut by the manufacturer to the precise dimensions of a wood template provided by Jon and the team.
Those templates are tricky. Jon shows us how creating a template for a kitchen counter involves absolute precision. Leisure Coachworks wants to have as few seams as possible in this shower. Unlike bathroom tile in your house, every seam in an RV shower is a place for a potential crack. This bathroom does a lot of moving!
To avoid those cracks the team measures and orders large, solid pieces cut to fit the exact dimensions of each area. Fewer seams and less sealant make for a reduced risk of leaks.
When those pieces arrive, they are dull. They need to be buffed and polished to a high shine before installation to get the appearance the team and the customer want. In this motorhome, there will be solid surfaces in more than just the bathroom.
Jon shows us the pieces for the nightstands, tabletops for the slide outs, a slide-out counter for extra workspace in the kitchen, and even a pop-up spice rack. Each was created from a precision-cut wood template provided by Leisure Coachworks.
One of the solid sections for the RV shower is so big that the crew will have to remove a piece of the shower wall for installation and replace it afterward. This level of customization ensures that the water from this nice big shower stays where it belongs. This is the type of planning and detail that the team puts into every project.
A Detour
As Jon and the team were working on this Fleetwood Expedition remodel, the customers requested space for an additional 40 gallons of fresh water.
Jon gives us a look at the intricate installation of two additional freshwater tanks. They needed to be placed carefully to tie in with existing plumbing and be out of the way of the storage area to avoid damage.
Each component of an RV upgrade or remodel has to fit precisely with the rest of the build. There is no room for error and Leisure Coachworks takes pride in the expert craftsmanship the team puts into every aspect of every job.
Accommodating special requests like this is a challenge. Jon and the crew love a challenge!
As we head into the RV interior to see where the solid surfaces are going to go, Jon stops to show us the entryway. It’s in the mock-up phase right now, with wood and metal stair riser templates that will eventually be replaced by custom mirrors.
We see the intricate detail that goes into something that looks simple: the platform at the top of the stairs. As Jon explains, it needed several customizations to be both functional and match the rest of the interior. No detail is overlooked when Leisure Coachworks is on the job.
Back on Track
One look at the interior shows us how far it has come from our last update. Beautiful new flooring and cabinets are in place and the new bench seating is taking shape. It already looks great but there is still work to be done.
Once we’re in the back of the coach, we get a look at the shower and the wall that will need removal. Fortunately, it’s a small section of an interior wall. The solid surface shower wall is just too large to install without taking it out.
That’s how custom RV remodeling goes. The team plans every detail, but they still have to be flexible and come up with solutions for unexpected issues. Every custom build needs tweaks and adjustments along the way. Knowing this before the project begins avoids a lot of frustration for the team and the customers.
Removing and reinstalling that small wall will be worth it. It allows that shower wall to be one piece, with no seam down the center to leak somewhere down the road. A big, beautiful shower like this becomes a burden if it causes water damage later.
It’s more than the solid surface walls that keep the water in this shower. The walls behind the solid surface are layered, starting with plywood covered with tarpaper, and a layer of PVC that covers the shower floor.
The next step is overlaying the walls with HardieBacker. What is HardieBacker? It’s a brand of cement backer board that acts as a substrate for tile on walls, floors, and counters.
The backer board supports both the solid surfaces and the minimal grout necessary in this shower. This substrate is made of cement and sand and helps prevent cracks and breaks. In some installations, HardieBacker is used in place of plywood. At Leisure Coachworks we use it in addition to plywood for even further protection.
After the HardieBacker is installed, the shower walls are painted with waterproofing paint. The crew now has an ideal surface on which to glue the solid surface walls and place the floor tile.
There are solid surface caps for the sides and bottom of the shower entrance for more protection and to create a cohesive look throughout the bathroom.
The shower area will be accented with tile that matches the shower floor. It will line the exterior area beneath the shower entrance as well as the walls around the outside of the shower, framing a custom mirror.
This entire space will be functional, cohesively designed, and look like it was always meant to be exactly as it is.
A Bathroom Break
As we said, the solid surface is for more than just the bathroom. Jon walks us through the bedroom, showing us where the pieces we saw in the shop will go. Two nightstands and a table will go in the bedroom.
In the living area, we see the full-sized desk Jon designed specifically for this customer and this motorhome. The desk has full-length drawers and a cabinet with a pull-out shelf and an outlet to house a printer.
All it’s waiting for is the solid surface top.
In the kitchen, we see the place for the countertop extension. It pulls out when necessary and stows away neatly with a simple push. We also see where the intricately cut solid surface countertop will go, with a stovetop and the pull-out spice rack. The final cut-out on the counter is for the sink.
Elsewhere in the kitchen, the dishwasher has been installed. This is a big, open space with a lot of room to cook. The team upgraded the slide out fascia with gorgeous dark cherry wood. An inset in rye and alpaca integrates the rest of the design colors.
The slide-out on the other side of the coach has the same cherry fascia with accents at the corners and overhead. Some of the seating cushions have been placed so we get a glimpse of how elegant the RV interior will be when the project is finished. The pleated back cushions fold down to reveal extra storage space.
Jon also shows us some of the detailed elements that increase function and integrate design on this Class A motorhome. An armrest with a cup holder echoes the color palette. A cherry wood back rail includes built-in USB ports and our Leisure LED touch lights are an understated, functional accent.
The seats have yet to be installed so the crew has enough space to bring in the solid surface pieces. That gives us a chance to admire the new flooring and the gorgeous overhead storage cabinets that line the interior of the coach.
Why Leisure Coachworks?
We’re proud to be the RV repair and design shop chosen for this project. This video shows how Jon and the team adjust, solve problems, rework, and keep trying until the customer’s vision comes to life.
Leisure Coachworks brings hard work, expert craftsmanship, and attention to every detail to every project. If you can imagine it, we can build it. Contact us to talk over your next RV repair, upgrade, renovation, or conversion project.
Jon and the team approach every project, from the smallest teardrop trailer to the largest bus conversion, with dedication, creativity, and a commitment to quality. RV living is special, and we’re here to make your motorhome or travel trailer match your RV lifestyle dreams.
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About Leisure Coachworks
Leisure Coachworks is a full-service RV repair and RV maintenance shop in Fontana, California. We work with most insurers and have the space and skill to take care of any motorhome, travel trailer, campervan, or bus. We believe that a well-maintained RV lives a longer life and gives its owners more great memories. We will help you design a maintenance schedule that is right for your vehicle and your RV trips.
Our talented, experienced technicians prioritize quality work and superior craftsmanship on every project. We love custom RV work and are proud of the many trailers, motorhomes, and bus upgrades, remodels, and conversions the team has completed. See some of these amazing builds from start to finish at Leisure Coachworks Videos and like, follow, and subscribe to our YouTube Channel to get updates when new videos arrive.
We love our RV community and support your RV lifestyles. For the DIY RV repair and maintenance enthusiast, we have a wide selection of RV parts at our online Parts Store. Find DIY tips and hints, along with some great RV living guides, on our RV Blog.
Visit us online or drop on by our shop to learn how Leisure Coachworks makes RV dreams come true every day.
