Build in NYS - Insurance Problems

[pchast]

Over the last 7-10 days I have been working on the driver side door
fitting for about an hour here and there. I inserted pine for hard
points to accept the hinges and door handle and cedar for light
stiffeners.





I have a question about installing the windows. How much support
do they need in a Foamy? Should I provide a Wood Frame?

Thanks,

[tac422]

Hi Pete,
Your construction method is exactly the same as The Big Pink.
Heres the link to where Mike built the window frames using 1x2's on page 2 of
viewtopic.php?f=55&t=44091&start=15

Then I swapped the windows out to manufactured windows, theres a good picture on page 1 of
viewtopic.php?f=55&t=56441

On the other hand, GPW didn't use wood on his Foamstream. ( his foam was thicker)
viewtopic.php?f=55&t=45027&start=1140

You might not need the wood, but I think the wood frames helped to provide a more secure attachment for the windows...

To answer your other question, I lightly sanded the foam before applying a coat of Glidden Gripper to attach the canvas.

Tac

[pchast]

Thanks TAC.

The references were a big help.

I intend to sand the foam with a palm sander and 100 grit(I have a ton of it) inside and out. I have lagging premixed compound to put down the canvas itself. I sent GPW a PM asking about his windows.

I'll move on to the other side door and wait to decide on the windows. I'm striving for light on the final due to the TV we have. I already went a little heavy on the floor by using a Zip wall board on the trailer bed at 47lb.

[pchast]

Its been a long, cold break. It was in the high 60's today and I got
out to the garage to do some more on the sleeper...

I cleaned up the dust and dirt that covered all. I set up the passenger
side and marked for the fender location. I actually got out again this
afternoon, routed spaces and glued in 4 inserts for the fender screws.

No photo's today.

[pchast]

Arghhhhhhh . Hard drive problem again. Lost the last couple of years photos.

I've been struggling to get an hour of work at a time in again. Perhaps 2 or
3 hours total a day. Still I keep poking along at it.

I'm using Western Red cedar for most of the wood work. So long sleeves and
PAPR, Hat are all protection required. I find the weight change of a panel is
almost unnoticeable with the amount of wood I'm using unless actually weighed.


I assembled the flat section of the top with the vent area framed.


I got the Passenger door stiffeners completed and the hinge blocks moved to where they should have been.


I worried about the strength of the door header so I inset a stiffener.

[pchast]

I did the door top support for the passenger side today.
I'll plane it flush tomorrow.

[pchast]

I spent a couple of hours this afternoon. Pulled off both wheels and made a support
for holding the walls vertical at the door jamb. Then screwed it down to the floor.
It took much of the time devising a method to clamp one wall at a time.

I'll take the big leap and GG one side in tomorrow afternoon. Its supposed to be in
the 60's and sunny.

[pchast]

Glued in driver side and back, fitting other panels.

Driver side


Attaching back, GG, messy.


View of temporary bracing.

[pchast]

The last few days steps...


Second wall and front gorilla glued.


fitting front 9" shelf


Back and 12" shelf


Check roof assembly fit

[pchast]

Yesterday and today...


Front inside of roof staves.


Outside view of glue-up and shelf wall fit out..
Using tape and TBII.


Back roof.


She caught me resting.

2 ft. more to fit and cut for full roof. Sanding, shaping,
then canvas before moving to wiring.

[pchast]

Glued in all staves and prebuilt flat section The roof seems solid BUT
when I look at the join to the wall in half of it part of the ends are not
glued together. There is a crack a third of the width of the wall.

I'm wondering if crack fill foam is good enough or I should inject
Gorilla glue????


glued in place with tb11. some wide seams taped for additional
gluing. Considering lighting placement so magic marker doodling
on the ceiling.


TB11 added to 'bad' seams.


Left strapped down for overnight. There are still bad seams
this morning.

[Shar]

Looks like you are starting to get to the exciting part- where it becomes more 3D!

[pchast]

Thanks. the box is formed. Just a few holes for doors and vents.
Fitting them and windows will be interesting. I need to do the
canvas first. Then lights and electric. Its more challenging at
each step.

[pchast]

Ah,,,

1.5" foam. It seems to be quite firm. I added a vertical stiffener
at the door latch side, full height. There are horizontal stiffeners
at the hinge locations and one in the door header. All stiffeners
are 1/2 x 3/4 cedar cut so the long axises and grain direction will
resist bending. The are glued with GG in tight, routed, mortises

I used 1.25" rafters every 8-12" between fitted staves. (ripped
western red cedar 2x8) The roof is stiffer than the sides. I can't
wait to see what adding the fabric skins adds to the structure.


Tonight I started to smooth things out with vinyl spackle and did a
light sand of the shiny foam skin on the Dow product.

Pictures tomorrow.

[pchast]

Starting to smooth out foam with vinyl Spackle.
Second pass at it yesterday.