Galley Door - Laminated Ribs

[kramergwt]

I've been thinking about a process that removes guesswork out of creating a good fitting galley door. I came up with the idea that I would rip some Sitka Spruce I have and can't use for my other project into 1/8" x 1.5" strips (Its a very light wood with long fibers that give it an incredible strength to weight ratio). Then with a 48" radius jig I should be able to consistently make top to bottom arching ribs by stacking up 12 laminations. I figure I could position 6 of them a foot apart for my 5 foot wide door. That would make such stiff ribs that the plywood shouldn't cause them to spring back and out of the 48" radius. Once I make the door, I can kinda make the rest of the trailer around the galley door to ensure a good fit. Even if there is slight springback, I can trace the profile of the ribs onto the sides to get a match. (I think I will go down another 1/4" on the sides so I can sandwich a soft rubber seal between the lid and the sides. I'm using System 3 T88 for glue because I've seen wingtip bows for antique airplane projects made with it and there is literally no springback and it holds it shape with a LOT of strength.

Has anybody done something like this? Anything I should be aware of? I think it'll look sharp and I can create channels in the ribs to hide wiring so it seems like a decent thought for several reasons.

Have the Kuffel Creek plans but using them only for general guidance.

All feedback appreciated.
Thanks

[pohukai]

Sitka Spruce... that's really nice stuff.

I did almost exactly what you described when I built the deck beams for my baidarka kayak that were made of spruce. I soaked the strips in water water for a few days using a capped 3" pvc water pipe. Then, clamped them over the framing and let them dry. When dry, I glued up the laminates using system3 epoxy. When I took them off the frame, I had no spring back and the deck beams were super strong.

I may do something similar when I do my hatch... but it won't be with spruce; it's hard to find.

[kramergwt]

Believe it or not a retired glider builder gave me 4 planks 16' x 6" x 2". I'm also building an antique plane but only 1 of the planks is airworthy wood. This seems like a good use of the remaining planks (at least some of it).

Funny you should mention the kayak. I got the Shade book on the strip built sea kayak last year and think that will be next after the tear. Do you ever go out on trips with the tear and kayak?

[pohukai]

Wow.. That's a lot of spruce. Some of that would be great for a skin boat (baidarka) http://wolfgangbrinck.com/boats/, but none come close to the beauty of a stripper.

I built one of Nick Schade's Guillemot's about 12 years ago using mostly red wood (when it was cheap), mixed with highlights of pine. Fully glassed, it was great for day trips but not rugged enough for harsh kayak multi-day trips off the coast of CA. http://www.rollordrown.com/fandf.html My guillemot was used on the cover of the Lexus SUV brochure years ago.

I'm still working on my teardrophttps://plus.google.com/u/0/photos/109287005282295320233/albums/5746508387867256129. It's taking some time to get back some of the skill lost over time since my kayak building days.

The teardrop is a perfect fit for all of the activities my wife and I do. I built a lockable bike rack inside my 4runner and I have a yakima rack on the roof for the kayaks. I'm not sure how much kayaking we'll be doing with the teardrop, but it is possible. The thing with kayaking is afterward spending time in the water there is a lot of clean up, especially if you kayak in the ocean. All your gear needs to be washed with fresh water to keep the smell from making you want to throw up.

You got to post some pics of your kayak when you start. Nick has done a fantastic job with detailing his technique for strip building. I modified it because I didn't want staple holes in my kayak for cosmetic reasons. I built that boat in about 9 months.

Take care and stay active.

Jim Gabriel

[kramergwt]

I will try and hang on to as much of that Spruce as I can for the kayak. Looks like you are pretty heavy into kayaking. That seems like a big trip out to those islands and back, fighting the chop of the ocean. Must be a completely different experiece than the rather calm waters of a lake. I have a plastic kayak that's good for some exercise and fishing. ...but think a nice homemade wood kayak will move a lot faster.

I read Nick's book and got the idea to finish my teardrop with woodstrips and fiberglass it. Tomorrow I'll rip a pile of spruce slats to about 1/8" and order some T-88. I can set up the jig for the galley hatch ribs while I wait for it to come. T-88 is great stuff.

The Guillemot is the one I was thinking of too. Do you still use it?

Your teardrop looks like it's coming along nicely. I think I am almost at the point you're at. Can't wait to get it usable! House projects keep getting in the way. Good to hear your wife will use it with you. Jury is still out on whether my wife will try it or not.

Take care.

[Irmo Atomics]

Just found this post... I made laminated hatch spars by ripping 1x4 SYP and gluing them up in a jig cut from a 2x8. There's no spring back because the long glue contact surfaces won't allow the strips to unbend; the wood will break before the glue releases. Can't give you any idea on how long they'll hold up, I just made them.