NV200: Making furniture doors in 15mm ply


Click for: NV200 Campervan build index, Also all Necessary tools used. Full conversion spec here. All photos taken during build

In my head, this job was easy – doh.  As ever, its a right sod and isn’t as easy as it looks on YouTube.

So, the way I did it, right or wrong, is:-

  • Measure where the door needs to be and the size
  • Cut rectangle MDF to the size of door
  • Use corner jig (ply with rounded corner and lips) and a flush router bit to round off each corner on the MDF door
  • Screw door to bigger bit of MDF and use router template guide to cut out a door from MDF (so you get a larger “negative” of the door (6mm straight cut bit)
  • Place negative template on “real” wood and mask, clamp, and use router with template guide to cut out real door.
  • Once cut, remove tape and hopefully its nice and neat!

Then route a T cut (1.6mm) half way though thickness of the ply and bang in the edging.

Easy as that lol!

(Need to practice for when doors will be on view!)

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