Generic Benroy Foamie in NE Wisco

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Re: Generic Benroy Foamie in NE Wisco

Postby Pmullen503 » Sat Jul 25, 2020 4:48 pm

Those were the wall insides? Covering one side can make the wall warp if it sits around too long.
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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Sat Jul 25, 2020 9:58 pm

Pmullen503 wrote:Those were the wall insides? Covering one side can make the wall warp if it sits around too long.


The previous pics were the exterior PMF on the walls. But, good to know. We were going to wait to PMF the interiors as we have to run a few wires inside and some anchor points for a headboard shelf first. I think we'll have to address that sooner than expected.

Thanks.
Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Sat Jul 25, 2020 10:11 pm

Installed the walls and lower 2/3 of the bulkhead. Will finish building the upper bulkhead tomorrow so we can add the ceiling panel and possibly start the roof. We'll regroup and discuss getting all the interior wall work done so we can PMF the interior soon.

Bulkhead installed.
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Temprary brace to square it up.
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One sidewall installed.
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Fastening second wall.
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Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Sat Jul 25, 2020 10:21 pm

We had some trouble yesterday with Great Stuff pushing buried cleats of wood proud of the surface of the foam instead of staying flush with the surface. I've read some posts that have warned about this so we wired the cleats into and through the foam to hold them in place. That didn't work and we ended up routing the protruding wood faces flush with the foam.

Andy came up with an idea to provide "relief valves" along the dados to allow the foam a place to escape from the back of the dado. He thought that we could drill weep holes at an angle along the dado for the foam to come through.

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As you can see in the following photo none of the foam exited the weep holes. It may be because we were very conservative with the foam application and maybe there wasn't enough excess to push through. Or the idea may not work. It's worth doing some experimenting in the future to see if this will relieve some of the expanding pressure.

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Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Sun Jul 26, 2020 3:29 pm

Andy headed back to Milwuakee after a marathon work weekend. We managed to almost get everything done that we hoped. Bulkhead is mostly installed with a little clean up to finish up. I'll be on my own with remote directions for at least the next two weeks so things will move along slowly.

I'll focus on the pmullen warning of warpage if the interior walls are not PMFd. I'll spend the next couple days organizing the wiring and plywood cleats to be installed then will PMF the interior.

Top section of the bulkhead work.
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And we tried an experiment with pressure relief holes around the bulkhead dados. Andy tried bigger holes with the hot wire gun. The jury is still out on this method. of course the bulkhead had little chance of being pushed out of place since it was anchored to the floor prior to glueing the last section. I'll try to document the process better when I anchor some ply cleats into foam over the next couple weeks.
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Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby Pmullen503 » Sun Jul 26, 2020 3:46 pm

TimC wrote:,....

I'll focus on the pmullen warning of warpage if the interior walls are not PMFd. I'll spend the next couple days organizing the wiring and plywood cleats to be installed then will PMF the interior.



Now that you've assembled the sides and bulkheads there's nothing to worry about. It matters only if you cover one side and let it sit for days. The panel can bow making subsequent assembly more difficult.
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Re: Generic Benroy Foamie in NE Wisco

Postby Pmullen503 » Sun Jul 26, 2020 3:52 pm

I'm curious how gluing the fabric to the trailer floor went. I did just the opposite; covered the interior walls and roof first and covered the outside after assembly.
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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Sun Jul 26, 2020 4:31 pm

Pmullen503 wrote:I'm curious how gluing the fabric to the trailer floor went. I did just the opposite; covered the interior walls and roof first and covered the outside after assembly.


Will have to let ya know on that. The flap is just dangling for now. Our intention is to glue it PMF style to the edge and underside of the 2" overhang and secure that with a trim piece that incorporates a drip edge on it. Not sure what we'll use yet. I'm thinking trim made from 1x treated lumber. The floor overhang (2") underside is already coated with black jack roofing tar. I suspect the TBII will not readily adhere to it. Thus the 1x treated to help hold it in place. The trim will have to wait until we have the PMF done on the roof.

Tim
Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby Pmullen503 » Sun Jul 26, 2020 8:21 pm

I wonder if you could use more black tar to stick it down. Worth a test on some scrap canvas.
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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Mon Jul 27, 2020 8:22 am

Pmullen503 wrote:I wonder if you could use more black tar to stick it down. Worth a test on some scrap canvas.

Good point. I hadn't thought of that option. It would definitly stick. It'd be messy, but I think it would work better than trying to glue with tbII.
Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Tue Jul 28, 2020 8:46 pm

Burying wires for headboard USBs and porch light and its switch. I tried hot glue to "tack" the wires in the channels, but, all that did was melt the foam and make a big mess. I ended up using homemeade 18g wire staples to keep them in the groove and then used PLP to lock them into place. Any suggestions of what to use to fill the void without making too much work. I have GS original, GS window and door. I'm thinking spackle and drywall mud would eventually just shake loose. The channels will be covered with PMF, so...

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Porch light switch location
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This homemade switch cover will mount on the above block.
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Playing around to get a layout for the electrical panel. It will include the items pictured. Not sure this layout will be final. I know the fuse block will require the most room for wires in and out so it might go into a hidden panel behind the rest of these. Also haven't decided on a main battery kill switch location. The pictured location will be behind a cabinet door and have easy access to reach in and power up the TD. I put my kill switch in TD#1 in the galley, but, that has proved to be a pain if I just want to turn on a light to get something out of the cabin or I'm just stopping for a roadside nap and want to turn on the ventilation fans.
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Left to right and top to bottom... Anderson Powerpole outlet for battery charger or to power a 12v appliance, 12 space ATC fuse panel with neutral buss, three banger USB/12v/voltmeter, switch to power voltmeter on/off, solar charge controller 10 amp, battery kill switch.
Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Wed Jul 29, 2020 6:02 pm

Burying more anchors for shelves and hooks.

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Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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TimC
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Re: Generic Benroy Foamie in NE Wisco

Postby ghcoe » Sun Aug 02, 2020 10:35 am

When you are ready to canvas the interior hit me up I can give you some recommendations to make it easier.

For a switch plate I use these https://www.lowes.com/pd/CARLON-1-Gang- ... 1000976020 . Just place it on the wall where you want it, trace around it with a sharpe, hot wire the foam out deep enough for the box, glue in with DAP Latex Caulk. They work great!

For gluing in your hard points I would recommend using DAP Latex Caulk or Gorilla Glue Construction Adhesive. It does not expand like the Great Stuff Does. I use to use Great Stuff a lot, but now I hardly use it at all because of the expansion issue. If I have some big voids and I want to use glue I will use it then. I like to use a bit around door and windows once they are installed. A small squirt will help keep the window/door in place going down bouncy roads.

I usually install the exterior canvas, now, once the body is assembled. I found it much easier to flip the body so I can install the canvas on a flat surface, rather than trying to apply the canvas to a vertical wall. The exception is the end walls though since it is hard to flip the body that way and still be able to work on them. It is also easier to glue the bottom flap without glue running down your hand.

Bottom floor coating is last just before applying the drip edge.

The hatch on my #1 is quite large and it works quite well. It came in at only 25lbs. so it is easy to lift without lift struts. I used flashing on the ends for attachment points and support for the latches and hinge. No other support was needed.

Good luck, George.
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Gorrilla Glue, Great Stuff and Gripper. The three G's of foamie construction.

My build viewtopic.php?t=54099
Working with flashing for foamie construction viewtopic.php?f=55&t=60303
Making a hot wire http://tnttt.com/viewtopic.php?f=55&t=55323
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Re: Generic Benroy Foamie in NE Wisco

Postby TimC » Sun Aug 02, 2020 2:18 pm

Thanks George. I'm going to review your build on the foam hatch before we get too far along.

Still not sure about how we are going to cover the interior. It might be a patchwork of canvas or other material. I get the idea of doing that horizontally but we are too far to have that option at this point.

Tim
Tim
Niagara, WI
My First Benroy Teardrop Build Thread - A 5x8 Woodie - http://www.tnttt.com/viewtopic.php?f=50&t=63575
My Second Teardrop (partial) Build Thread - Started August '16 - http://www.tnttt.com/viewtopic.php?f=50&t=66939
#3 My son's Benroy Foamie team build - Started July '20 - http://www.tnttt.com/viewtopic.php?f=50&t=72877

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Re: Generic Benroy Foamie in NE Wisco

Postby ghcoe » Sun Aug 02, 2020 7:55 pm

I walk through how I did my interior about half way down this page http://tnttt.com/viewtopic.php?f=55&t=54099&start=405 .
I walk through how I did the ceiling about 1/3 of the way down here http://tnttt.com/viewtopic.php?f=55&t=54099&start=600 .
George.

Gorrilla Glue, Great Stuff and Gripper. The three G's of foamie construction.

My build viewtopic.php?t=54099
Working with flashing for foamie construction viewtopic.php?f=55&t=60303
Making a hot wire http://tnttt.com/viewtopic.php?f=55&t=55323
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