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Doug33's avatar
Doug33
Explorer
Nov 03, 2014

paper thin bunk plywood

Yesterday I winterized the TT. In the process I had to access the hot water heater and the bypass valve. The water heater is located under the lower bunk. My particular TT model has the double bunks, which are very comfortable and easily accessable for even adults. I've actually slept in the lower bunk a couple times.

In order to get to the water heater I have to remove the mattress and then unscrew the "plywood" sheets and lift it out of the way. I was shocked at how thin the wood is. I knew I was in trouble, because when I crawled towards the back of the bunk to unscrew the far end, my knee started to go right through the wood, making a huge crack in it.

I know manufacturers are trying to save every almighty single pound from a TT, but this is absurd. I can't believe this wood supported anyone without collapsing.

After finishing winterizing, I didn't bother putting the wood back in place or screwing it down. If there is a warm spell, I will remove the thin wood, and replace it with something else that is stronger. I was thinking using a pressboard, but I know they are pretty heavy.

Has anyone else replaced their bunk plywood, and if so, what did you use to replace it with. I'm not too worried about adding a few pounds, but I would still like to keep it as light (and cheap) as possible.

Are their synthetic (plastic composite) alternatives to plywood or pressboard?

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  • DutchmenSport's avatar
    DutchmenSport
    Explorer
    Nov 03, 2014
    You may find the reason they used something so thin is because the wood needs to to bend in order to get it in place. Even something as thin a 1/4 inch plywood will not have the flexibility to bend.

    In my Springdale (former trailer), the water pump was located under the couch. When I winterized, I had to remove the plywood under the cushion. It was screwed down. I unscrewed it and it was paper thin also. This also bothered me, until I tried taking it out. That's when I realized it had to have flexibility to bend into the right position. I debated for a long time about changing it. I never did. And ... I never had a problem with weight on top of the couch either.

    If you are really concerned, my thoughts would be to leave the original and just put a second one on top of it. Something very thin. The paneling used in showers would work very well as a second level, and still still have the flexibility you may need to position it in place.

    While you are at it... how thin are the sheets under the cushions of your dinette? Mine were made of the same material as the couch.

    Edit:

    I just looked up your camper model, and the bunks are in the corner. You will not be able to remove or replace a sheet of plywood, get it in there without bending it somehow. BUT!.... if you split it into 2 halves, and then built a reinforcement where the 2 halves (seam) come together, you might have the space to get something heavier in there (in 2 halves). This would work, after looking at some photos of what your camper model looks like.

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