The Charlie Project

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

Postby Forrest747 » Thu Jan 12, 2012 1:47 pm

Jennie started her new job as amedical examiner, so i get a few hours alone with me and the mistress Charley. So I taped all the wires into place with gorilla tape and then added the white insulation. next build i will go two states away to get the blue insulation, just cleaner and easier to work with. The plan was to avoid cuts was to put down a 3/4 inch layer of insulation and where the wires crossed just fit the panels in place. still had to do alot of cuts. so next time will have to figure that one out.

Going to route out the joints tonight and cut the forward 30 degree angle. i also need to cut it to the proper width. Reading over a couple of the other post i will have the kids pick up more glue before we put it on.

Had to fix one outlet that wasnt powered up and it was a loose neutral connection.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Postby Forrest747 » Sun Jan 15, 2012 4:05 pm

The roof is on. That was after I built Jennie some shelves for the kitchen. I had planned on using the spline methid of joinging the panels together. Did not go so well. I put the first one on glued and screwed it in place. The insulation did not compress as I had hoped so at the joint there was a 1/4 inch between the roof and spar. So I cut a four foot by 3 inch wide and slid it inbetween. I tried to add the spline and it just was not going to work. Removed and butted the panels together. With it screwed in place I the cut the spline in 9 inch lengths and hammered them in from the side put the first 4 feet in and then went to the other side and hammered the rest in from the other side. Repeated for panel joint # 2. Worked pretty good I think. Have to figure out to level the front end joint where it sticks up about 1/2 inch too high. Thinking of using the planer or the router I just don't know this is all new to me. With the doors I am going to start from scratch. going to use 1/4 inch plywood and then frame it out and then the cherry for the interior. will save weight, get the round porthole windows right.
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"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Postby Forrest747 » Thu Jan 26, 2012 12:12 pm

Well the sawdust has been flying. used the planer and the router to get the joints close together. two buckets workth, as soon as i get my belt sander back from a co-worker i will get them flush. Well last night i hooked her up to the jeep and went around the neighborhood to see how it felt. Jeep seemed to pull just fine. lowered the hitch by about 2 inches i noticed. i do need to find out the tongue weight. also took the time with Charley out of the garage to sweep up underneath her.

Still alot to do but getting closer.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Postby parnold » Thu Jan 26, 2012 12:30 pm

That first trip around the block is fun isn't it?

Hearing you complain about the white foam is making me rethink things.. I was leaning toward using it due to availability, but I don't want to make the build any more difficult than I need to.

Keep up the good work!

:thumbsup:
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Postby Forrest747 » Thu Jan 26, 2012 12:43 pm

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Here is some of the insulation dust from the white stuff and then some of the blue insulation. as you can see there is alot of difference. I will never use it again . I hate it more than fiberglass insulation and that is alot of hate.

It really does feel different towing her and knowing that maybe within a month will have paint on her.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Postby parnold » Thu Jan 26, 2012 12:57 pm

That's exactly what I need blowing around my driveway and yard... NOT!

Guess my next project is to locate a source for the blue stuff.
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Postby Martiangod » Thu Jan 26, 2012 1:16 pm

What your looking for is Extruded Polystyrene
It can be any color depending on maufacture, Dow is blue, Owens Corning is Pink, I've seen Yellow, purple and green. So don't go by color
If it ain't broke, fix it till it is

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Postby PSBreen » Thu Jan 26, 2012 7:34 pm

The weather has been slowing me down a bit so it's great to see someone making some progress. It's looking great.

I agree on the white foam. The plain foam without any backing just crumbles when you cu tor sand it. I prefer the pink or blue foam myself. They are both available in my area, but the pink appears to be available in more thicknesses.
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Postby Forrest747 » Tue Feb 07, 2012 9:21 am

I still have some white insulation which I plan on putting in the doors and then after that it will be banned in our home. Just been sanding the edges and filling in screw holes. Then more sanding and more sanding. i can see why some just do the alum skins doesnt have to be as pretty underneath. it will be worth it though

Came home and 3 hours later covered in sawdust. Life is good

02/13/12 Update:

Well spent part of Friday night and saturday making the face for teh shelfs inside. got them all patched and sanded. hopefully i will have some help or at least some peace and quiet since we have a ton of cousins here. Fits in there really snug so hopefully a few coats of black stain and installed by wednesday.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Re: The Charley Project 02/13/12

Postby Forrest747 » Tue Feb 14, 2012 5:50 pm

Image

Here is teh inside frame for the shelfs. put the first coat of stain on them. thought they looked pretty good.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Re: The Charley Project 02/13/12

Postby Martiangod » Tue Feb 14, 2012 9:49 pm

Looking awesome, that cherry is beautiful.
And your sure bounce back, don't you :applause:
If it ain't broke, fix it till it is

Chris

Deep in the Heart of Nowhere
The topper viewtopic.php?f=50&t=58140, gone to a new home to be converted
into an ice fishing shack...FREEBIE !!! for a nice young family
The trailer viewtopic.php?f=50&t=48156
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Re: The Charley Project 02/13/12

Postby mckenney56 » Tue Feb 14, 2012 10:52 pm

I hope the new hip will make you good as new.

Question. Where can I find those hinges you used on your doors?
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Re: The Charley Project 02/13/12

Postby Forrest747 » Tue Feb 14, 2012 10:59 pm

I am happy with the new hip and two new knees. I got the hinges from a wrecked jeep. A lot of the parts I use are jeep wrangler parts. Including the fuse block.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Re: The Charley Project 02/13/12

Postby Forrest747 » Mon Feb 20, 2012 11:21 am

Well it was a fruitful weekend and week. Finished the shelf face framing,  stained it, installed it and then realize hey you didn’t urethane it. I also rough cut and routed the other trim pieces to the interior. Looked pretty good. I will sand them a little smoother and then another coat of stain. Then install the trim pieces when I get the snap fastners that I ordered. Measured the length of the sleeping area and it is 73 inches.

 

Went to the RV show this last weekend. Gave me a lot of good ideas, simple changes I can make. I now plan on having the sink flip down, instead of slide out. I also saw a little guy 5 wide and silver shadow. Got a little daring and laid down in it. Nice and cozy but I did not like the cabinets over my feet, just a little too tight. Not my thing, it just felt too cramped. I could also very easily see over the roof. Charley I can but I have to be on my tippy toes. It was interesting that there were only 2 teardrops out of all the RV’s maybe a close standy but it was slightly large.

 

Did give me a few other ideas like bunks that fold on the outside over the fenders. Double as a table, Jennie also thought of maybe adding an awning we shall see.
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Re: The Charley Project 02/25/12

Postby Forrest747 » Sat Feb 25, 2012 9:59 pm

Spent this week getting the roof to ceiling trim on. Went well and now cut the wall trim pieces cut and first coat of stain on. I had the Saturday to myself so spent it out in the garage. Hung up some peg board I bought and swept up. Started on the tongue box and put some of the cherry in the shelf area. A lot done life is good
"All the success on the trail can not compensate for having square headlights"

"I've got a fever and the only prescription is more cowbell!"
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Forrest747
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