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Quote: Originally posted by Marcrod on 25/6/2013

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No, I salvaged the bottom shelf, but had to make the top shelf with a 30deg cut. I used a cheap Rhobi jig saw, that has the ability to tilt the blade and then just stuck to the line really well. If you still have the old shelf, I would sand it down until you reach good wood as then add a layer of chip board or 3mm ply to reinforce. I used a piece of hardwood for the shelf (to stop it warping when it dries properly) and this cost me more than the frame (£18.50 for a 2m x 150mm) piece.

I have finished now and it actually looks ok. I will have to make some tape from the left over wallboard to cover a couple of cutting mistakes, but overall I'm impressed at how easy (technically) the job is. It's just time consuming and requires patience.

For the weatherproofing of the main spars I used some aluminum tape on the outside, stuck about 1inch onto the ABS and enough so I could wrap a flap around the wood. I then used some liquid rubber (£10 ish off eBay) to give my old seals the bet chance of being water tight and painted it onto the main spars (that are covered in ally tape) and carefully over the edge of the seals that touch the ABS.

Take care when it comes to re-fitting curtains, as I guessed and now have one curtain that needs to be slightly adjusted.

If you do need to take the front overhead lockers out, then I found there were screws coming down from the underneath the roof. I took the drastic option of basically, whilst removing all the ones I could, ripping the wood from the ceiling. I destroyed the holding wood (try not to damage the furniture it's self, but then added a couple of screws where the down ones were to screw it back up. To get rid of the hanging screws I used a pare of tin snips to snap te screws flush to the wood above.

I hear the weather is good this week. Good luck

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