Kicking Back in Comfort
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RV mechanic working on a kitchen area wall
Tired of the same old floorplan but still love your RV? Remodeling the living room — and adding Thomas Payne recliners — can be a game changer
By Bob Livingston / Photos by Rich Dubnow
W

hen it comes to buying a brick-and-mortar home, realtors know that the mantra is “location, location, location.” In the RV arena, salespeople are well aware that it’s changed — to “floorplan, floorplan, floorplan.” Granted, the RV still needs to fit a budget, but it first needs to fit a buyer’s lifestyle — and budgets have been known to “grow” in order to accommodate that “perfect” floorplan.

Finding it, however, sometimes takes a few tries. What looks good at first may prove to be unworkable after a being on the road for a while. But unlike moving furniture around in a stationary residence to change the layout, RV owners who get tired of the floorplan have fewer options. Most, in fact, ultimately trade their RVs for one that offers a more suitable floorplan for their changing lifestyle — which can be very expensive when depreciation enters the picture.

A good alternative — and one that has gained a lot of traction lately in the RV world — is to remodel, taking advantage of new furniture and entertainment/convenience options.

We consulted with owners who just couldn’t live with the floorplan in their 2015 Tiffin Phaeton 40-foot motorhome any longer and stuck around to document the results. In this coach, an L-shaped couch (or often referred to as J-lounge) dominated the living room, with the TV mounted on the wall shared by the “jack-and-jill” bathroom. The bathroom was in fact the driving reason for buying this motorhome — the mid-coach bath is a good feature for those wanting better access to the bathroom from the bedroom. But as they discovered, watching TV from the couch was uncomfortable — and the opposing dining area felt out of place visually to the owners.

Also, since the owners did not entertain overnight guests, the bed built into the couch served no purpose and was never used — and it crowded the driver’s seat when turned toward the living room. After a number of years complaining about the floorplan (and wishing for a theater seat arrangement), they finally decided to remodel the living room in lieu of selling the motorhome and buying a new one.

original floor plan of the lounge area
remodeled floor plan of the lounge area
Original floorplan featured a large J-lounge, which occupied a great amount of space, and a small recliner. Television placement was not ideal. The results of the remodel are dramatic: the J-lounge and recliner were replaced with Thomas Payne recliner, extra storage and a wine cabinet. The TV, meanwhile, was moved from the far wall and placed within the credenza using a power “televator;” its former location is now a home bar.
the original credenza/dinette was functional
remodeled credenza/dinette
Across from the couch, the original credenza/dinette was functional but the owners felt it was detached from the rest of the living room décor. It was the perfect foundation for relocating the television and expanding the countertop. When the TV is elevated, it covers the window, but can be lowered quickly using the remote control. It does provide a perfect screen view from the Thomas Payne theater seating ensemble.
A couple of factors solidified the decision to remodel. They found the perfect theater seating arrangement from Lippert’s Thomas Payne collection, and they hooked up with a master furniture craftsman, Dave Borkholder, who runs Custom RV Furniture in Milford, Indiana, close to the Elkhart “RV metropolis.” Borkholder is an Amish furniture builder who follows the culture and traditions of old-world craftsmen. His shop is on the outer edge of his expansive farm, which has no electricity or modern conveniences. He travels by horse and buggy and invites customers to park on his property and enjoy the solitude of natural living. Borkholder has even signed up to be part of the Harvest Host overnight stay program.

Borkholder is no stranger to the RV industry, having spent more than 20 years in various capacities, primarily working in factory cabinet shops. He has also rehabbed houses, capitalizing on his ability to build fine furniture. While he offers a number of pre-designed tables and workstations, his forte is to dig in and figure out how to customize interiors.

To get the project started, the owners visited Borkholder’s farm and spent a couple of days discussing options. Borkholder listens to the owners and then works with them in designing a plan from scratch; there is no need to come to his shop with plans from an outside source. He’s incredibly creative and, knowing his way around RVs, can make decisions that offer convenience and value. Of course, the popularity of his work means you can’t just drop in; figure on about two months lead time to get an appointment.

Complying with his Amish culture, Borkholder does not use a computer. He does have a phone that’s kept in the shop, which — along with his generator and power tools — is allowed by Amish rule in order to make a living.

Once the plan was penciled in, the owners had to do some shopping. Settling on the theater seating was a no brainer. Offered exclusively through Lippert, the Thomas Payne collection boasts an extensive number of options, and once you sink into the company’s theater seats, you’re hooked. For this project, right- and left-hand recliners (part numbers 2020129336 and 2020129337, respectively) were chosen with Norlina fabric upholstery. The light beige fabric has a handsome texture that is very smooth to the touch. This is a departure from the Ultraleather upholstery originally in the couch, and desired by the owners for its warmth in colder weather and somewhat better resistance to scratch marks from their dog and cat. Once the center console (part number 2020129339; 12 x 34 x 31 inches), with matching fabric is added, the entire ensemble is about 67 inches wide; only 4 inches of space is needed to the back wall to allow for full reclining. Fully extended, the recliners stretch 64 inches.

mechanic dismantles the dining structure starting with the cabinetry

The teardown started with dismantling the dining structure. Most the cabinetry was retained, including the table that matched the other counters in the motorhome.

the credenza was removed from the wall
The credenza was removed from the wall and taken into the cabinet shop to expand the countertop, making room for the television lift.
Dave Borkholder uses plywood core veneer when building the new cabinet sides and tops
all the pieces of the cabinetry are connected with pocket screws and glue to ensure structural stability
Custom cabinet builder Dave Borkholder uses plywood core veneer for the new cabinet sides and tops. The veneer has a proven track record for durability in RVs. All the pieces of the cabinetry are connected with pocket screws and glue to ensure structural stability. This painstaking procedure pays off for superior longevity under stressful RV conditions.
Panels on the inside surface of the armrests control the power headrest, lumbar support, lighting and recline functions and to activate massage and heat features. Counting the two in the center console, there are a total of four chrome cup holders with color-adjustable lighting activated by touching the trim ring. In the center console is a large storage compartment suitable for remotes and incidentals; a flip-up 120-volt AC power center with USB charging ports is built into the top surface.

Power ports are also built into each armrest, designed to accept an optional reading light, fan and wireless phone charger. The same ports can also be used to accept a unique wine caddy, a small swivel desk and a clip-on armrest tray. We didn’t get a chance to check these items out during the install because of a backorder situation.

Getting the theater seating through the front door of the motorhome was easy since the ensemble is modular and the backs can be removed. Mounting is facilitated by interlocking hardware that requires no tools, and it only takes a few minutes to assemble the entire set-up; the seats and console were plugged into a nearby 120-volt AC outlet. The owners elected to forego fastening the seats to the floor, since the motorhome exhibits good ride control; it’s probably best to screw them to the floor in travel trailers and fifth wheels. The Thomas Payne recliners are priced at $749.95 each and the center console is $259.95.

Considering the Thomas Payne seating took up less space than the factory L-shaped couch, the plan also called for additional cabinetry on both sides of the theater seats, providing quite a bit of increased storage and counter space. Originally, a small recliner was tucked into the space behind the couch and immediately adjacent to the TV. With the addition of the twin Thomas Payne recliners it wasn’t needed; the remodel plan called for a wine cooler to be built into matching cabinetry. A modern-looking wine cooler was purchased from Best Buy for $799. The two-door, dual zone Insignia (model NS-BC2ZSS1) is designed for mounting inside a cabinet and can hold 21 standard wine bottles and is also suitable for water and soda bottles. A nice benefit of purchasing appliances from Best Buy is the ability to procure warranty service just about anywhere. This was a strong consideration for the owners, who live in the motorhome fulltime.

Borkholder fabricates metal brackets
Borkholder begins work on the flip-up counter extension on the dinette that will open when the TV is lifted into position
the existing valance frame is put back in place
Components for the television lift must be integrated carefully into the wood structure to assure smooth operation; Borkholder fabricated the metal brackets as well as all the woodwork. Although Borkholder follows strict Amish tradition, exceptions are made for using power tools needed to make a living.
Work begins on the flip-up counter extension on the dinette that will open when the TV is lifted into position. Hinge for the flip-up counter must be aligned perfectly to prevent binding when the TV “pops” out of the structure. Once that’s accomplished, the existing valance frame is put back in place.
Borkholder fabricates metal brackets

Components for the television lift must be integrated carefully into the wood structure to assure smooth operation; Borkholder fabricated the metal brackets as well as all the woodwork. Although Borkholder follows strict Amish tradition, exceptions are made for using power tools needed to make a living.

Borkholder begins work on the flip-up counter extension on the dinette that will open when the TV is lifted into position
the existing valance frame is put back in place
Work begins on the flip-up counter extension on the dinette that will open when the TV is lifted into position. Hinge for the flip-up counter must be aligned perfectly to prevent binding when the TV “pops” out of the structure. Once that’s accomplished, the existing valance frame is put back in place.
A key element for this remodel was moving the TV from its aforementioned factory location to a position across from the theater seating to provide a perfect viewing posture. Borkholder retained the front portion of the original credenza — countertop, cabinets and pull-out table — and reconfigured it, using a power “televator” for the 47-inch Samsung 3D TV and by extending the countertop. This new structure provided additional counter space for entertaining and allowed for full use of the large window when the TV is tucked into its retracted mode — without losing any storage space. Both dinette chairs were retained, but the plan is to replace them at a later date.

The only caveat was rewiring the TV to the satellite receiver, broadcast antenna, surround-sound components and cable connection. Previously the wiring logjam from the factory was reworked by Advanced Satellite, a Junction City, Oregon, company specializing in RV entertainment systems. Months before the Tiffin’s interior redesign, upgraded stereo components, speakers and controls were added to enhance listening pleasure. Advanced Satellite, being familiar with the system, was contracted after the interior upgrade to re-route the cabling to the new TV location. The project was completed flawlessly at a cost of $1,500.

The wall vacated by the TV allowed for an unplanned opportunity to convert the area into a bar that holds wine, spirits and wine glasses. Borkholder designed a system to control the bottles and glasses and offer a beautiful touch to the living room, aesthetically and functionally — and it was built in such a way as to prevent the glasses and bottles from dislodging from their positions when the slide is in travel mode.

the TV Is removed from the original mounting position on the shared wall with the bathroom and attached to the lift mechanism built into the dinette/credenza

The TV was removed from the original mounting position on the shared wall with the bathroom and attached to the lift mechanism built into the dinette/credenza. Original countertop was retained and extended to house the television.

the completed theater seating ensemble
It’s hard to tell that the new dinette/credenza was not original. Countertop extension for the TV lift blends perfectly. When the TV is elevated, it covers the window, but can be lowered quickly using the remote control. It does provide a perfect screen view from the theater seating ensemble.
Borkholder removes furniture from a wagon
Borkholder moves the new pieces into the motorhome
Thomas Payne furniture was shipped directly to the Borkholder’s shop in Milford, Indiana. A horse-drawn wagon was used to transport the two recliners and center console for loading into the motorhome. The Thomas Payne modular design makes it possible to move the pieces into the motorhome, without having to remove one of the cockpit seats. These pieces will also fit through the front door without incurring damage to the upholstery.
Once the plan was fleshed out, it took four days to complete the project. All the cabinetry framing and doors are made from maple hardwood and the tops and sides are plywood veneer; pocket screws and glue are used throughout the structure. The existing factory finish was meticulously matched using industrial-grade stains, which cannot be found in local hardware and big-box stores. Cost for Borkholder’s creations, including the television lift, was $3,992.

Obviously, RVs are made to be on the road, and that’s the rub. Hardwoods can sweat up to 16%, according to Borkholder, which can lead to splitting. In order to compensate for the stresses imposed by a moving vehicle and changing climates, veneer tops and side panels were chosen which, said Borkolder, provide superior strength and longevity. (I can attest to the quality of Borkholder’s work; he built new furniture for our fifth wheel three years ago and his upgrades have endured more than 30,000 miles of torturous highways without any signs fatigue. And under full-time living conditions, the countertops show no signs of wear and tear.) Owners looking to remodel their RVs should be cognizant of weight and come to the party armed with accurate figures from a local scale. Of course, some of the additional weight will be offset by the removal of the original furniture and fixtures, but it’s also important to know the capability of the slideout (especially in a fifth wheel or trailer) and be aware of the impact of any shift in weight balance. The weight changes in the project motorhome were not an issue.

In the end, the interior remodel opened up the living area visually and added a big dose of luxury that complemented the factory décor beautifully. With the cockpit seats turned toward the living quarters, the entire living room becomes a much warmer environment for entertaining guests — something that was less feasible with the original L-shaped couch. The ability to sink into the new Thomas Payne seating, recline to an almost horizontal position, adjust the lumbar support, get a massage and warm your tushy is a game changer.

If the owners can stay awake, they can gawk at their new surroundings.

a Border Collie rest on a recliner in the motorhome

Each recliner attaches to the center console via special brackets that lock the units together without using tools. Seat backs can also be removed without the use of tools. Here, Brody finds his new seating just right for watching the other components take shape.

Borkholder measures a cabinet frame

Framing for the cabinetry is constructed using maple hardwood. Walls and countertops made from the same wood do not hold up well under RV conditions. Cabinet doors and drawers are also made of hardwood.

Borkholder runs a cabinet frame through a sanding machine
Sanding machines are used to ensure a perfect fit at the frame joints and overall consistency.
Borkholder measures his cabinet, mid-build
Borkholder works on the larger cabinet
One of the two side end tables starts to take shape. These cabinets, placed on each side of the Thomas Payne theater seating add valuable countertop and storage space. The larger cabinet is designed to shroud the wine cooler, which will occupy the space originally used by the stock small recliner.
mechanic prepares industrial grade stains
Industrial grade stains are carefully mixed to make sure they match the original décor. It took a number of attempts to get it right. Once Borkholder is satisfied, he stains a new piece and places it next to an original and asks the owners if they can tell the difference. “Thumbs up” means it’s a go.
stain is applied using a cloth or from a spray gun, normally reserved for the larger pieces

Stain is applied using a cloth or from a spray gun, normally reserved for the larger pieces.

finishing touches are made to one of the end cabinets, making sure the stain is applied evenly
Finishing touches are made to one of the end cabinets, making sure the stain is applied evenly. You won’t see any runs on these components.
the rear end cabinet is fit into place between the wine cooler cabinet and theater seating
Once finished, the rear end cabinet was fit into place between the wine cooler cabinet and theater seating. The rear cabinet has two doors and two shelves; the smaller front cabinet has only one door.
Borkholder makes a final adjustment to the wine cooler
Final fitting of the wine cooler and end cabinets fill the space beautifully. When done, it was virtually impossible to tell that these components were part of a remodel. A portion of the window is covered by the wine cooler cabinet, but the owners deemed that as inconsequential.
Borkholder adds stylish shelves to securely hold wine/spirits bottles and wine glasses

An opportunity to re-utilize the space vacated by the television presented itself while placing the new furniture. Borkholder added stylish shelves to securely hold wine/spirits bottles and wine glasses.

view of the completed new wine bar
The new bar for storing wine glasses and bottles blends beautifully with the fireplace. Space formally occupied by a recliner that was never used adds a huge element of luxury and function.
view of the Thomas Payne theater seats
controls for reclining and adjusting the lumbar support, and activating the massage, heat and lighting functions are flush mounted on the inside surface of each seat arm
pop-up power station is built into the top portion of the center console
The Thomas Payne theater seats are upholstered in a stylish fabric, rather than Ultraleather, which is smooth to the touch. Seats recline into an almost horizontal position providing tremendous support and comfort. Trying to stay awake is not an easy task.
Controls for reclining and adjusting the lumbar support, and activating the massage, heat and lighting functions are flush mounted on the inside surface of each seat arm. There’s also a USB charging port on each side. Pop-up power station is built into the top portion of the center console. Provided are 120-volt AC and USB charging outlets. The new recliners also feature two lighted cup holders built into the center console, which opens for storage.
view of the Thomas Payne theater seats

The Thomas Payne theater seats are upholstered in a stylish fabric, rather than Ultraleather, which is smooth to the touch. Seats recline into an almost horizontal position providing tremendous support and comfort. Trying to stay awake is not an easy task.

controls for reclining and adjusting the lumbar support, and activating the massage, heat and lighting functions are flush mounted on the inside surface of each seat arm
pop-up power station is built into the top portion of the center console
Controls for reclining and adjusting the lumbar support, and activating the massage, heat and lighting functions are flush mounted on the inside surface of each seat arm. There’s also a USB charging port on each side. Pop-up power station is built into the top portion of the center console. Provided are 120-volt AC and USB charging outlets. The new recliners also feature two lighted cup holders built into the center console, which opens for storage.
view of the remodeled lounge and wine bar space

The completed remodel adds beauty and comfort while opening up floor space in the liv- ing room. A nearly perfect blend of theater seating, cabinets and additional countertops transforms the area once only occupied by a couch and small recliner.

Sources:
Advanced Satellite
(541) 607-8968
rvtv2go.com

Custom RV Furniture
(574) 354-2905
customrvllc.com

Lippert
(574) 535-1125
lci1.com

view of the remodeled lounge and wine bar space

The completed remodel adds beauty and comfort while opening up floor space in the liv- ing room. A nearly perfect blend of theater seating, cabinets and additional countertops transforms the area once only occupied by a couch and small recliner.

Source:
Advanced Satellite
(541) 607-8968
rvtv2go.com

Custom RV Furniture
(574) 354-2905
customrvllc.com

Lippert
(574) 535-1125
lci1.com