The bigger hole method is fine too. I have done one that way, even left
the rear A/C in and working. The curved metal arch must be cut out and a
flat replacement put in it's place. Bolt a new piece of plywood into the
rear ceiling hole. Since you already did the small hole method it would
be a fairly simple step to enlarge the roof hole and add the folding
upper bed. Measure carefully and make sure the new ceiling is low enough
for the folded bed and pads to fit between it and the top.

The flat rear ceiling of the Westy is lower and crowds the lower living
space a bit more than the arched ceiling. The small hole method result
is much more spacious inside but less storage without the rear closet.
We own both and travel a lot in both. When we were younger the narrow
lower Westy bed was fine and climbing up to the upper bed was less
difficult. Now we are more comfortable living in our roomier homemade
version. YMMV

Mark

.Dave Vickery wrote:

>
> Having done this now, I do wonder why we don't just cut a bigger
> hole.  The
> 42" x 42" hole works good, but the roof arch is what makes fitting the
> upper
> bunk a trick.  Why not just continue cutting most of the way to the rear
> (including 1 roof reinforcement) which would remove the arch.   You could
> then re-create the flat section with plywood and some reinforcement.  The
> arch is a couple inches.  By flattening that out, there would be
> plenty of
> space for the normal bunk and avoid the welding etc.  Anybody ever try
> that?
> .....................