In the beginning, there was sawdust..

General Discussion about almost anything Teardrop or camping related

Postby looped » Tue Jul 08, 2008 1:18 am

the router bit..

I think it just might make it to the end of the build. it is showing signs of giving up, mostly visual, but it is still cutting good so i wont complain..

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this is showing the hole that will be the center for the rear side marker light.. this was pre measured and drilled on both outside layers (as well as the front one but that one worked out well

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it was supposed to line up with these holes in the inner wall to make wiring a snap should any access to them be needed due to light needing replacing or whatever.

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but despite measuring twice and cutting once it didnt....

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So instead of drilling new holes where the access holes are, ( was tired from a long day at this point and wasnt thinking, could say wasnt thinking clearly but the fact remains i plain just was not thinking at all).. i just inserted a drill bit from the outside, prayed and pulled the trigger...


this was the result after using the router to get some access.....

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Now the reason this was needed to be done is i realised this after gluing it up with pl number something super duty stuff and poking about 30 screws in there to clamp it. dont have the clamp collection of a more experienced builder yet. but i do have plenty of epoxy putty filler stuff. No pic of the outside, but trust me there is alot of screws in it all countersunk nicely.


Now to hold the walls to the floor is a aluminum plate that is drilled and countersunk. it is broken into three parts per side due to the fenders mounting on u bolts. just seemed cleaner and more heavy duty than using washers, this will be getting some of the pl glue to help it hold as well.. the screws i will be using are stainless steel deck screws that will be drilled in then hand snugged to hopefully eliminate snappage..

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these are the walls as they sit now.. just letting the glue fully do its thing. i thing this build was the most times i have lifted those weights since i got them. sad but true.

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Now the insulation part.. yes i know for insulation that would qualify as a shoddy job at best. but. that insulation isnt there to make a cooler out of it, they are there (glued in with pl numbersomething) for sound deadening. when its done i want it to sound as solid as it is.

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the inside walls and ceiling will also be covered in ozite (automotive carpet) have three rolls of black in the corner of the garage waiting to be chopped to bits and used

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a new thing my white collar friend, instead of griping about having access to the garage he never uses actually showed some interest in what i was doing today.. at this rate i just might have a helper by 2010! :)


one question bout the hatch notch on the outside walls,, when making the hatch spars will i need to trace the outside line or the inner? seeing that i am on teardrop time i went ahead and cut a larger version of the piece just in case the humidity warped the original. the line used was the outside line

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Postby looped » Tue Jul 08, 2008 1:32 am

oh and yes that is pink duck tape. i have a friend who wrote a book called "100 uses for pink duck tape" and i got an advance copy as a gift. yes the tape came with it.
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Postby Miriam C. » Wed Jul 09, 2008 9:45 am

:applause: :applause: :thumbsup: Walls up are a beautiful thang! Looks great and I love the pink duct tape. I used Mike's weights for clamps too. 8)

On the hatch spars, I think you need to trace the outside before you cut the notch. If you don't you will have them too short. That is if your hatch sits over the wall. :thumbsup:
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Postby looped » Wed Jul 09, 2008 1:00 pm

Thank you. today after i do some painting i plan to go over there with my dremmel and soldering iron to reverse my hasty decision with the rear sidelight thing.

also will be playing with the ozite as i plan to cover the sides and inner roof before assembly.

this filler putty says it will work on wood, fiberglass, steel and plastic with no shrinkage. we will soon find out how true that is.

After seeing the price of automotive paint i have decided to vinyl the top and paint the sides with duplicolor. i will still need to applu clearcoat to the sides but that will hurt less than the 90 or so a gallon paint for spraying.

This will have a benroy style hatch but with a double staggered seal -_ on the sides.
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Postby 2bits » Wed Jul 09, 2008 10:14 pm

Yeah the outside line is what you want because the inside line for the spars is probably going to be deeper that what is cut out for the hatch.
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Postby looped » Thu Jul 17, 2008 12:45 am

well tonight i went over there and dry fit the pieces together., ya know to see how they will fit.


Im suprised at how square it is, the 26 inch side of the square showed 1mm deviation on the end. this will be easy to correct. next is to take it apart and assemble again with glue and git er dun!

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Postby looped » Wed Jul 23, 2008 5:53 pm

today i worked on it some more. took the walls and ceiling off and then after putting ozite on the inside roof put it all back together with glue this time. Also got the spars glued and screwed on.

yep you guessed it the camera was at my place. i will be going back out there in a little bit and will have it with me though
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Postby 2bits » Wed Jul 23, 2008 7:56 pm

uhh It's supposed to be square?? :lol: better man than me! Looking good!
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Postby looped » Thu Jul 24, 2008 6:35 pm

well heres the pics of my recent work to this. did a vast assortment of PITA work in the past couple days. extended the floor back a little, routed some wire and got it kinda hooked up. got the roof and sides put back on there with glue this time. filled some holes and cut the hatch spars.

the pic with the board and aluminum piece wedged in there is my attempt to convince the walls that they dont want to bow inward. the reason that the spars have fat ends is because the radii goes to 5 inches and thats to do two things, one to reduce flexback and 2 to keep any moving cargo from lodging itself into the spot and preventing the opening of the hatch


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Postby looped » Thu Jul 24, 2008 6:48 pm

oh yeah the spars were cut on the bandsaw. the router bit is starting to cut fuzzy.. seeing that its my first router bit and first router, and that its a 1/4 collet. im actually suprised that it lasted this long.
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Postby looped » Sat Aug 02, 2008 8:27 am

yesterday i braved the heat to go and work on the hatch and to test the lighting before i sealed it up.. the wiring is sound and the hatch is together, kinda. the basic frame is built will need to trim the outermost spars a little bit more for the double seal i will be using.

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Postby Miriam C. » Sat Aug 02, 2008 8:43 am

Wow! That is a great hatch lid. :applause: :thumbsup:

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nice looking

Postby deano » Sat Aug 02, 2008 9:49 am

that looks nice keep up the good work
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Postby looped » Sat Aug 02, 2008 10:23 am

Thank you for the kudos, i appreciate it.


went to the first saturday sidewalk sale early early (1am) this morning it is kinda a fleamarket specialising in computers and whatnot. well this time there was a big ryder van full of what appeared to be junk,, well once they unloaded it i noticed this pair of 1 1/2 ton jack stands.. so i picked them up and took them to the money man and asked how much,, he said 15 for the pair but i haggled him down to 10 for them :D


they are in the boot of my car at the moment so no pic just yet.


after being up all night pacing around the sale (every time i was ready to go, more venders would show up) i am ready to get horizontal..



good (ehemm) night, y'all
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Postby 2bits » Sat Aug 02, 2008 11:10 am

Nice looking hatch! :thumbsup: That si going to be strong! I haven't been to first Saturday in years!
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