Method for manufacturing a bunk for a vehicle

A method for manufacturing a bunk assembly for a vehicle, the method comprising:

• thermoforming an upper shell having an upper flange;
• thermoforming a lower shell having a lower flange;
• applying adhesive between the upper flange and the lower flange;
• pressing the upper flange and the lower flange together to form a support panel;
• trimming a main flange of the support panel;
• forming a fill hole and a vent hole in the lower shell, the vent hole having a first diameter;
• providing a foam cure fixture comprising a bed and a lid, the lid being pivotable between an opened position and a closed position;
• installing the support panel onto the bed with the lid in the opened position;
• pivoting the lid to the closed position such that a fill port on the lid is aligned with the fill hole of the lower shell;
• locking the lid;
• filling the support panel with fill material through the fill port and the fill hole and such that air contained within the support panel is vented through the vent hole;
• enlarging the vent hole to a second diameter to form a mount hole, the second diameter being greater than the first diameter;
• and
• mounting hardware to the support panel at the mount hole.

A method for manufacturing a bunk assembly for a vehicle, the method comprising:

• thermoforming an upper shell having an upper flange;
• thermoforming a lower shell having a lower flange;
• applying adhesive between the upper flange and the lower flange;
• pressing the upper flange and the lower flange together to form a support panel;
• locating a jig on the lower shell, the jig comprising a first guide hole and a second guide hole;
• drilling a fill hole through the first guide hole;
• drilling a vent hole through the second guide hole, the vent hole having a first diameter;
• providing a foam cure fixture comprising a bed and a lid, the lid being pivotable between an opened position and a closed position;
• installing the support panel onto the bed with the lid in the opened position;
• pivoting the lid to the closed position such that a fill port on the lid is aligned with the fill hole of the lower shell;
• locking the lid;
• filling the support panel with fill material through the fill port and the fill hole such that air contained within the support panel is vented through the vent hole;
• installing the support panel onto a drilling machine that comprises an automated drill;
• operating the automated drill to redrill the vent hole to a second diameter to form a mount hole, the second diameter being greater than the first diameter;
• and
• mounting hardware to the support panel at the mount hole.