CNC Build: The Bed and Breakfast at 4 years and 40,000 miles

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

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. ;)
KC
My Build: The Poet Creek Express Hybrid Foamie

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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:
Image

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:
Image
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...
Image

Add cauls as required...
Image
... 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:
Image
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:
Image
... 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.
Image
From the other side:
Image

Around the door, too:
Image
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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For build info on our former Silver Beatle teardrop:
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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:
KC
My Build: The Poet Creek Express Hybrid Foamie

Poet Creek Or Bust
Engineering the TLAR way - "That Looks About Right"
TnTTT ORIGINAL 200A LANTERN CLUB = "The 200A Gang"
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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.

Brad
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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.

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

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

Very nice progress!
Things I have for sale on craigslist:
http://albany.craigslist.org/search/?ar ... catAbb=sss

Things I have for sale on eBay:
http://www.ebay.com/sch/merchant/seansmith
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Re: CNC Build -- ...aaaand the hatch is skinned

Postby capnTelescope » Sat Sep 27, 2014 7:56 pm

With the roof out of the way, :chicken: I could move on to skinning the hatch. This was much more straightforward than the roof. The hatch skin is two pieces, an upper and a lower. Both pieces got bent at Custom Sheet Metal. The upper piece got a simple 90 bend along the top edge, and the lower piece got a hem, bend around the bottom hatch board and a transition angle to the hatch surface. Then I pre-bent a curve into both pieces.

Upper:
Image
The 90 top bend is on the right. EHB tape goes along the bottom edge, shown here on the left.

Lower, drilled for screw holes and ready to goo:
ImageImage

The lower piece goes on first and gets screwed along the bottom edge:
Image

The upper piece comes next. Gooed around the edges:
Image

Top edge:
Image

I couldn't contain myself... unclamped and peeled:
Image

Now I can put the taillights back on and wire them up. Almost roadworthy.

While we're on the subject of hatches, I made (another) newbie design mistake. I have three hatch ribs, which means one is in the middle, right where I wanted to put my hatch latch-handle-turny thing. :x . I can move it off center, but still near the middle, or I can put it to one side nearer the edge. What does anyone think about any of this?
I'll burn that bridge when I come to it.

Brad
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