CNC Build -- Right Galley Trim Panel and Left

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Re: CNC Build -- preparing to skin the roof and hatch

Postby capnTelescope » Tue Sep 02, 2014 9:36 pm

KCStudly wrote:Hey, I get more replies from my mothers cooking and my eating habits than I do from my build!

I'm keeping it clean. :angel: You won't find any food porn in this thread. Unless you post it for me. :roll: ;) You do seem to eat well. :thumbsup:

Meanwhile, back at the build...

The day started with the UPS guy dropping off a long cardboard tube. :P My molding arrived from Vintage Technologies. :chicken: Everything arrived in good condition, and I was ready to go to work.

They (whoever "They" are) say you should pre-bend your trim before you go to actually apply it. Sounds perfectly sensible to me. So I got with it. I got two kinds of trim molding, their HT09 and the HT11. The HT09 will cover the outer gutter wall trim and the top of the galley walls. The HT11 trims the length of the roof/wall corners.

Since "trimming" seemed to be the theme of the day, I first trimmed those areas around the hatch that I had to built up before (dramatic re-enactment).
Image
The router bit is a CMT 806.690.11 flush trim bit with a 2" cut length. I used the insert plate for my router table as a base, to give me more stability.

Results were good! The wall comes up flush to the hatch skin on both sides. Right:
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Left:
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Trying to bend the trim to the wall profile wasn't very productive as the trim springs back pretty much to where I started. I needed something with tighter curves. Just happened to have...
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That is an offcut piece of the ply I cut my hatch spars from. Roughly the same profile only a tighter curve. This worked pretty good, and I was able to further curve the trim by running the trim piece over a corner while applying moderate pressure.

Here's the rough bend for the left side of the Tear:
Image
Kinda looks like one of those "chalk around the dead body" drawings. :frightened:

I've been wanting a nice bend on both ends of the roof skin. One to tuck under the front end, and one in back to transition the roof into the top galley gutter. The trouble is, the Tear is 5 feet wide, and most bending brakes apparently only go up to 4 feet. At least, the one at Tech Shop does. (Danger ahead) So I got to thinking... :thinking: could I make a quick and dirty brake that would work good enough for 3 or 4 bends in .032 Al? I had everything I needed: 3 2x4s and 3 good door hinges. Why not try? The bend on the front end doesn't really show, so it can go first. I get the strong feeling that I'm about to learn something. :NC

Here goes:
Laying out the hinge-y part:
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Rout a space for the hinge pin to go:
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Screw the hinges on, and assemble:
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Clamp the ... uh ... Clamper board so it clamps the work piece along the bend line:
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OK. The first thing I learned is that even .032 Al needs more muscle than I have here on my knees with bare hands and no leverage. Let's raise it up a little and bring out the XL Super Bar:
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That wasn't much better. Let's put it up on the sawhorses. Only a little bit better. Oops, game delayed on account of rain:
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It was a nice little shower, about a tenth of an inch according to the official CapnTelescope electronic wireless rain gage. This gave me a chance to think. :thinking:

What if I turned it upside down?
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Hey, that looks like I'm halfway there already!

Success! :P
Image

close-up:
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Not bad. It's OK for the front end bend, but I want better for the back. I guess I'll have to find a sign shop or something.

Thanks for stopping by! :beer:
Last edited by capnTelescope on Sun Oct 19, 2014 8:37 am, edited 1 time in total.
I'll burn that bridge when I come to it.

Brad
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Re: CNC Build -- preparing to skin the roof and hatch

Postby KCStudly » Tue Sep 02, 2014 10:35 pm

I think siding brakes are much longer and typically will do thin material, such as yours. If the sign shop thing doesn't pan out, maybe try siding contractors. :thinking:
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Re: CNC Build -- preparing to skin the roof and hatch

Postby KCStudly » Wed Sep 03, 2014 9:45 pm

Hey, check it out, Mike had grilled pizza and smoked pulled pork!!! :thumbsup: :lol: :thumbsup: :lol:

Sorry, couldn't help myself. A food porn endorsement by our (bow down and place forehead to ground) TNTTT founder has me feeling pretty righteous! :lol: :lol:

I'll stop now. ;)
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Re: CNC Build -- preparing to skin the roof and hatch

Postby capnTelescope » Thu Sep 04, 2014 10:54 am

KC, you are bad to the bone! :lol: (Pun not entirely unintended.)
I'll burn that bridge when I come to it.

Brad
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Re: CNC Build -- Finally, skinning the roof

Postby capnTelescope » Thu Sep 25, 2014 10:46 pm

It's been a while since I posted. Life got in the way of fun, plus I caused myself some problems on the build that I had to work around. Then I gave my left index finger a mighty whack so it was unbearably painful to type. It's been so long since I posted, I had to go back and read my last post to find out where I was. I was getting ready to skin the roof and hatch, by the way. :roll:

While I was busy with the other so-called "important" stuff, I kept picking away at the build, but nothing spectacular. Until you look at the pile of pix and have to write it all up. So, here goes:

Last time, I was needing some nice bends in my roofing sheets. A company not far from the house named "Custom Sheet Metal" filled the bill perfectly. With a name like that, it had to work. Trading some bucks for some bends and shear cuts got me back on track.

The roof skin is three pieces. I like to call them the "front", "middle" and "back". The front goes in the front, and so on. Pretty cool system, isn't it? The front piece is the one I bent with the 2x4's. It got to go first:

Tuck the bend under the floor with plenty of sealant:
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The rear piece has a bend that acts as flashing into the top gutter:Image

The middle piece connects the front and back with EHB (Extra High Bond) tape:
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Word to the wise... If you're going to use EHB tape, clean the metal surfaces with acetone/lacquer thinner/mineral spirits to degrease before you tape.

Stick everyone together, strap 'em down...
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Add cauls as required...
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... and let everone get acquainted.

Why did I mention cleaning before taping? I didn't do it, and the front joint failed shortly after removing the straps. :fb

I pondered that situation, cleaned up the mating surfaces, pre-bent the front piece a little and tried again. This worked better, but there was still a pretty large gap at the front of the middle piece that did not pass inspection.

Third time's the charm... I said to "heck" with the high tech adhesive tape, I'm gonna rivet the damn thing. So I did:
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Note the tab in the foreground.

The other reason the second try failed inspection was that there was unacceptable slack in the front skin piece. I had to ponder the solution for this, and came up with the idea to EHB the tab to the front piece, hook onto the tab with a ratchet strap, and pull hard. This time, the EHB worked as expected of high tech stuff, and the riveting went swimmingly. A plastic chisel from Harbor Fright made short work of the three tabs, and I'm in high cotton. If this fails, I'll go find the 60" wide stuff on a roll and do over like I should have done it in the first place.

At this point, I wanted to put on the corner molding and be done so bad I could almost taste it.

But, like me, you'll have to wait until I finish the next step before that. It's coming right up. Don't go away, the next post is coming in a few minutes.

:beer:
I'll burn that bridge when I come to it.

Brad
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Re: CNC Build -- Finally, skinning the roof

Postby capnTelescope » Thu Sep 25, 2014 11:43 pm

OK, break's over, everyone back on their heads.

As I was saying, there was another step before I could take the final step to finish the roof skinning. :?

It seems that I have a problem following directions sometimes. After Tony.Latham took the time to 'splain skin floating to me, I went ahead anyway and stapled down the left side skin as if it were going to try to escape. I thought I was working close enough to the top edge that the corner molding would cover up. But nooooo, :x not even close. This wasn't going to look good at all, but I didn't want to get another $75 sheet of Al and start over. LCG IX is coming up in a month. It's crunch time.

Here's a typical staple divot. Multiply this by an embarassingly high number:
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... and to my eye, they look that big and that ugly. Ewwwww! Oh, and I did it around the door too. :oops: As if this weren't enough ugly for one wall, there's about an inch at the aft end that isn't covered where I had to build up to match the hatch. :cry:

Remember that wall skin I messed up on the CNC? It's about to become useful. I cut a trim strip from it on the CNC, and whaddaya know? It fit the wall profile nicely! :thumbsup: On the back end, I added an inch to trim by hand later. Goo and clamp.
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From the other side:
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Around the door, too:
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It almost looks like it was planned that way. :thumbsup:

I let the goo cure a while and took care of some minor Bravo Sierra. Came back later and trimmed the fantail and it's Molding Time. Woohoo! :chicken:

It looks good from this angle. It doesn't show until you get up close. :thumbsup:
Image

So the cabin is officially skinned. The hatch gets it next.

Thanks for stopping by! Stay tuned. :beer:
I'll burn that bridge when I come to it.

Brad
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Re: CNC Build -- Finally! Skinning the roof

Postby jeporter25 » Fri Sep 26, 2014 12:20 am

Turning mistakes into "design elements" is a sign of a true craftsman. Great solution!
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Re: CNC Build -- Finally! Skinning the roof

Postby aggie79 » Fri Sep 26, 2014 8:49 am

Excellent recovery Captain!

I don't here many folks saying it, but if you have an aluminum clad teardrop, I found installing the aluminum and trim to be the hardest and most time consuming phase of construction.

We'll touch base at LCG.

Take care,
Tom
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Re: CNC Build -- Finally! Skinning the roof

Postby KCStudly » Fri Sep 26, 2014 9:16 am

Well played. It does look like you planned it, and adds a little "texture" or shadow line, making your build unique. :thumbsup:
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Re: CNC Build -- Finally! Skinning the roof

Postby capnTelescope » Fri Sep 26, 2014 10:59 am

jeporter25 wrote:Turning mistakes into "design elements" is a sign of a true craftsman. Great solution!

Thanks JE. Welcome to my humble thread. I was always told to do it perfectly or paint it red. (Why do I get the feeling that I've said that several times already? :NC ) I used up the first quart of red and went back for a gallon. :D

BTW, no post on your build since July? You're losing momentum.

and...
aggie79 wrote:Excellent recovery Captain!

and...
KCStudly wrote:Well played. It does look like you planned it, and adds a little "texture" or shadow line, making your build unique. :thumbsup:

Thanks, guys. Paint it red, etc. :)

aggie79 wrote:I don't here many folks saying it, but if you have an aluminum clad teardrop, I found installing the aluminum and trim to be the hardest and most time consuming phase of construction.

Amen to that. This seemed to take forever. My hatch design added a lot of extra work to the process, too. If I build another one someday, I'll be able to simplify that considerably.

aggie79 wrote:We'll touch base at LCG.

I'm really looking forward to meeting you & Linda, and getting to see the Silver Beatle.

Thanks again, all, for the kind words. :beer:
I'll burn that bridge when I come to it.

Brad
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Re: CNC Build -- Finally! Skinning the roof

Postby jeporter25 » Fri Sep 26, 2014 7:20 pm

BTW, no post on your build since July? You're losing momentum

Nope I have just been too busy camping in it to post. I know bad me. :oops:
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Re: CNC Build -- Finally! Skinning the roof

Postby capnTelescope » Fri Sep 26, 2014 8:43 pm

jeporter25 wrote:I have just been too busy camping in it to post.

That's the best excuse there is. :thumbsup: In that case, keep camping guilt-free. :D
I'll burn that bridge when I come to it.

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Re: CNC Build -- Finally! Skinning the roof

Postby tony.latham » Sat Sep 27, 2014 11:22 am

Hey! Bro!

I LIKE the looks of your edge-job fix. You may be starting a fad.

Tony
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Re: CNC Build -- Finally! Skinning the roof

Postby capnTelescope » Sat Sep 27, 2014 11:29 am

tony.latham wrote:Hey! Bro!

I LIKE the looks of your edge-job fix. You may be starting a fad.

Tony


Hey back, Bro. Thank you. Thankyouverymuch. I always wanted to be a trendsetter. :roll:
I'll burn that bridge when I come to it.

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Re: CNC Build -- Finally! Skinning the roof

Postby GuyllFyre » Sat Sep 27, 2014 3:48 pm

Very nice progress!
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Things I have for sale on eBay:
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