G-Man,
I am a cabinet maker by trade. I’ve sold the business to my brothers so I have a great connection. They have both a custom cabinet shop and a solid surface top shop.
Yes I made a template of the top, picked out the Corian I wanted to use, sent them the template and had them build the top. I did the install myself.
Find a solid surface shop and have them template the new top for you. If they do the template then they are responsible for the new top fitting correctly. In my particular situation I was able to fasten the new top on the right end to the box built around the fridge. On the left end I made a Corian support that attached to the underside of the new top and then attached the bottom of that support to the chase that runs along the floor on the passenger side of the bus. You may not have a chase like that in your bus, but if not you should be able to come up with something even if you have to run a support to the floor. In the center, the old table had a corbal underneath with some alluminum mounting hardware attached to it. I simply remade a new corbal (less deep than the original because the new top dosen’t come out as far) modified the alluminum hardware to fit the new corbal and then reinstalled the new one back into the same holes as the old one.
I talked to Liberty about how the old corbal was mounted to the wall. They had actually welded metal in the wall and tapped it so that the screws screwed right into it. Therefore I couldn’t just run wood screws into the wall and have them hold anything. I had to go right back into the exact same holes as before using the same screws. It’s not hard, just have to make sure you make the new parts just right.
One suggestion, make your new top 20″ deep at the shallowest point. I went 17″ on mine and wish it were a few inches deeper. I may still have them make me another top and replace this one just to get the extra depth. Even at 20″ it would still stick out from the wall a foot and a half less than the table did.