Dusty Mark's 5 x 10 Build

[Mushin]

Thx for the info on the blinds, pricey lil things! The costs add up don't they!

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[Dusty Mark]

You're welcome and yes they do. Once I knew how much this build might cost at the quality level we wanted, I sold three little boats that I had built and a small sailboat to fund this project. I could have purchased a brand new Little Guy Silver Shadow 5' x 10' for the amount I have in this build, but I like mine better!

[Mushin]

Yours is definitely special, a beautiful build and a place for the puppy, win win!

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[KCStudly]

I could have purchased a brand new (insert OEM brand name here) 5' x 10' for the amount I have in this build, but I like mine better!

Amen brother, amen.

[aggie79]

I could have purchased a brand new (insert OEM brand name here) 5' x 10' for the amount I have in this build, but I like mine better!

Amen brother, amen.

I'll double that "amen".

[justageorgiaguy]

If you wanted, you could probably splice an IR extender into the a/c wiring. http://www.rvpartsnation.com/rv-electro ... Al6d8P8HAQ


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[Dusty Mark]

Good idea. I thought about the IR extender, but decided to go low tech with line-of-sight little windows. It looks like the air conditioner system is going to work out well with those modifications!

[Dusty Mark]

I trimmed the galley, painted the final coat on the underfloor storage covers and applied the final coat of varnish to the air conditioner trim.



I built up the side wall with 1/8" by 1 " aluminum to make it even with the roof line. That also supports the roof trim I applied in the next step quite well.



I'm using Frank Bear's techniques, from Vintage Technologies, to seal and trim the galley walls to receive the hatch.



Close-up of trim. I managed to pound the bottom bumper trim to shape without cutting a bunch of miters.



Ready for turn signals/brake lights.



Upper galley trim on passenger side.

Tomorrow I'll start working on the galley hatch...

[Dusty Mark]

I've been getting out doing some other activities the past couple of days, but I did get the galley lid frame started.



Clamped in place with a plywood spacer to simulate the exterior plywood skin. I used 5/4 white pine for the end caps and 1/2" Baltic birch plywood for the ribs. I'll add cross ribs and mounting plates for the license plate holder and dome light tomorrow. I'm hoping that I can fit the slam latches before I skin it and they'll still fit after the skinning process...



Pocket hole joinery holds the ribs into 1/4" deep dadoes. Top pictured.



The bottom cap needs to be hand planed flush with the ribs.



It looks like I have the proper setbacks for the trim to rest properly on the wall edge and create a good seal all the way around.

I hope to skin, insulate, and wire the lid tomorrow.

[Dusty Mark]

Plywood is applied to the outside and inside of the galley lid.



Exterior skin applied and the two layers of 3/4" foam insulation are being fitted around the bracing and ribs. The groove down the middle is for the wiring.



Extra reinforcement and attachment point for the lid support.



Slam latch hardware will attach and pass through this extra layer of wood.



Applying beads of foam glue to hold it down.



Applying polyurethane glue to frame edges to hold the plywood skin.



Stapling the 1/8" plywood down. One issue with using 1/2" plywood for the ribs is that the staples are so close to the edge of the 1/8" plywood that it chips. This will be covered with aluminum trim, so not really a problem.



The license plate light and the dome light are back-to-back. This is convenient as I cut an access slot (covered by the dome light) for installation and any future repairs.





The lid stiffened up nice with the inside layer of skin applied. It appears to be straight (without twists.) Lid weight at this stage of construction is 30.3 pounds.

I'll let the glue set a bit before I apply CPES to the outer skin and varnish to the inner skin. I plan to build an angled box (similar to my fan base) in which to install the dome light so that it is pointed straight down when the lid is up. I'll apply the red aluminum and mill finish trim two days from now.

[KCStudly]

Looking very nice, indeed!

[Dusty Mark]

Thanks! The test will be if it rests tight enough to not need extra weatherstripping to prevent leaks...

[retep]

Your build is progressing very well. I am very grateful you are sharing all the details. It is looking incredible. Thanks Peter

[Dusty Mark]

Thanks! It will be about 3 1/2 months from start to finish...not bad for an amateur builder. I wish that we'd come up with the idea a month sooner since this is starting to impact our summer activities. For instance, we haven't continued our trek north on the Superior Hiking Trail yet. I did this in a worse way last summer when I built and completely outfitted three layout duck hunting boats for my hunting crew. I need to get back to furniture building and stop these huge projects.

[Vedette]

Your build looks wonderful!
Thanks for all of the pictures.
3 1/2 months is not long for all of the work you have done.
Wish my build only took that long???
Good Roads
Brian & Sandi