CapeBuild Build Journal

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

Re: CapeBuild Build Journal

Postby Capebuild » Fri Nov 19, 2021 8:16 pm

Hello eLink. Hope your build is going well... I haven't seen any posts from you lately... nice to hear from you.

I kind of struggled a bit with the front bump out, but in the end all seems to have turned out well.... or okay. Got the insulation done and applied the outer layer only to realize I forgot to add blocking.
That wasn't too bad a screw up but I'll need to use some longer screws to attached the aluminum moldings in place.... but wrapping the .156 okoume around the roll pans was a challenge in that no matter how careful I was the wood cracked going around the curve. Not too bad, but bad enough. So when I got to the top radius I wet it. Wet it continually for about an hour. Kept wetting it with wet rags. And slowly, using clamps, forced it around the bend. Got to the last inch or so, all was going great, ...... and then CRACK...... Argghhhh. Patched it with some titebond mixed with sawdust. When that dried, sanded it. And then applied bondo to rework the curve. Made a template to check the curve. Probably should have used some of that "bendy birch". Anyway... all good now. I think when I install the outer roof layer where it bends around the front roll pans I may kerf the underside and fill the voids with PL Premium. Will see. I may also try to get some bendy birch for that section, but getting it is not an easy task. Otherwise, will finish up the wiring and insulate the ceiling next.

John
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wet.jpg
wet.jpg (146.89 KiB) Viewed 231 times
side.jpg
side.jpg (237.63 KiB) Viewed 231 times
3-4.jpg
3-4.jpg (214.93 KiB) Viewed 231 times
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Re: CapeBuild Build Journal

Postby Capebuild » Thu Nov 25, 2021 10:28 am

11.25.21

I decided to add another layer of ply to the front bump out. I noticed there was a bit of unevenness when holding a straight edge across the surface, a high spot in the middle, a dip at the corners..... etc. Bending the ply around the forms did not work so well with the first sheet with some cracking happening....... so..... with this additional layer of okoume I kerfed the underside where it would bend around the curves of the roll pans and the top curve. I also added some strips of ply to the existing surface to build up the low areas (think lath walls under plaster), sanding them down to be even with the high spots and then bondo in areas to build up. I put some hot water on the areas that bended and stapled it in place with PL adhesive. This worked out much better. Pretty flat and even with no cracking around the bends. Happy.

Also completed the insulation in the ceiling. After some bondo and clean up around the seams I'll install the roof ply.

Thanks for looking.

John
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new front panel.jpg
new front panel.jpg (176.99 KiB) Viewed 188 times
kerfs.jpg
kerfs.jpg (149.42 KiB) Viewed 188 times
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Re: CapeBuild Build Journal

Postby JasenC » Sat Nov 27, 2021 1:48 am

Those tight bends can be tricky, sounds the the water did the trick.
I'll be done when I'm finished, if that's not fast enough, take a number.

Build Thread https://www.tnttt.com/viewtopic.php?f=50&t=74269
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Re: CapeBuild Build Journal

Postby noseoil » Sat Nov 27, 2021 10:24 am

Bending poplar is good stuff to use for those tight bends. Instead of having 3 skins which run perpendicular to each other, they are all in the same direction, so it bends into a sharper radius than a normal 3 ply lamination.
Build log: viewtopic.php?f=50&t=60248
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Re: CapeBuild Build Journal

Postby Capebuild » Sat Nov 27, 2021 11:51 am

noseoil wrote:Bending poplar is good stuff to use for those tight bends. Instead of having 3 skins which run perpendicular to each other, they are all in the same direction, so it bends into a sharper radius than a normal 3 ply lamination.

Thanks Tim.... I wish I had gotten "something" that would like to bend a little more easily (bendy birch or the poplar you mention)... for now I think I'm done with the pieces that need such tight radius bends..... but next time I'll be ready :)

John
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Re: CapeBuild Build Journal

Postby Capebuild » Tue Nov 30, 2021 6:15 pm

11.30.21

Big milestone.... .installed the roof yesterday and removed the clamps today. Routed the edges flush and cut out for the roof fan. Did some touch up here and there.
Next I'll start thinking about the galley hatch.

John
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roof clamps.jpg
roof clamps.jpg (145.37 KiB) Viewed 105 times
roof .jpg
roof .jpg (645.59 KiB) Viewed 105 times
other side 3_4.jpg
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Re: CapeBuild Build Journal

Postby Capebuild » Mon Dec 06, 2021 6:11 pm

12.6.21

Got a few days of good weather last week and put 3 coats of urethane on outer ply layers.... so now ready to install the aluminum sheathing when the good weather rolls around..... like in April. :(
urethaned.12.6.21.jpg
urethaned.12.6.21.jpg (235.06 KiB) Viewed 62 times


Today received another sample of window gasket for the front window. This one seems to be just about perfect. I wanted to cut the polycarb a bit larger than the opening and have it sort of sit on top of the aluminum (above the aluminum). The only downside is the recess that mates with the cabin body is sized for .125" body. When I add the okoume plyand the aluminum the thickness winds up at .196"..... it seems to tightly fit the okoume without the aluminum ..... so I'm probably going to have to cut the aluminum back from the okoume opening. So be it.... if that's what works.
The scrap piece is the same thickness as the polycarb I'll be using.

John
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gasket.jpg
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Re: CapeBuild Build Journal

Postby Onajourney » Tue Dec 07, 2021 1:21 pm

John - I have been waiting for you to work on the window. You changed gears a little on the trim. What was the reason not to use the TRIM-LOK EPDM? I assume you're going to use .07 aluminum. Seems heavy. I am going with .04 and hope I can squeeze .25 wood and .04 aluminum in the .25 Trim-Lok. Chris
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Re: CapeBuild Build Journal

Postby Capebuild » Tue Dec 07, 2021 5:06 pm

Onajourney wrote:What was the reason not to use the TRIM-LOK EPDM?


Hi Chris.... I'm using .040 aluminum. Not sure where the .070 figure showed up.
Regarding the window gasket, the one shown in the picture from the previous post is Trim Lok model LK1660. It is EPDM material. It accepts .250 glass and accepts a .125 body panel.
My issue is, the glass fits great. The trailer's body where I as going to fit the trim is to be .196". I get that from the .156 okoume ply layer and add the aluminum sheet (.040") to get .196". So that's
a bit bigger than the .125 spec.
I think what I'll wind up doing is cutting the aluminum a bit wider than the window opening, and gingerly size the aluminum so it fits just inside the edge on the seal.... the gasket will only be
trapping the .156 okoume ply... which seems to be stiff enough. I've attached a screen shot of the Trim Lok catalog (page 38) with the LK1660 I'll be using.

John
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locking gaskets.jpg
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