go ahead, call me crazy !

[felixx]

I just discovered this thread and wow oh wow

[dave campbell]

I just discovered this thread and wow oh wow

wow thanks felixx ! just making it up as i go. haven't derailed yet

today's update---still chuggin' along with the sticks----popping in steel when i think i need it. for instance---- ceiling backing over the doors. had to zap in some straps. nearly completed the interior studs now. tomorrow (sunday) i will put in some more wee angle tabs to help secure the flooring, and start gutting the cargo trailer. having a party here on the 12th----a perfect time to get help lifting thunderdome onto its new platform !!

pl fest.JPG (28.65 KiB) Viewed 1778 times

below--- just over one of the doors

centre ceiling.JPG (26.74 KiB) Viewed 1778 times

this is just over the front windows

over the front window.JPG (25.67 KiB) Viewed 1778 times

cheers all and thanks for looking ! i haven't been commenting but i have been lurking around and enjoying the cool builds !!

[lincolnlerner]

My two cents, on insulation, boat building and weird shapes, and things. I'd skin this frame on the outside. Run all my wiring , pipes, etc, needed in conduit. Then have the insulation shot on from the interior.. Closed cell, which doesn't transfer condensation. Then skin the interior. Expensive, yes. But when you're already doing the job you're doing on this build its well worth it.

While I have not run through this idea completely, it does seem to cover some of the comprehensive technical difficulties.
Could a "rubber swim cap" over the frame then the "one-piece" be placed?

Have a lot of unknown territory here. But have to say this is a great build. Wish I was "hand-on" with this build. Course I probably would of messed something up. Post some pics when you can. Thanks! Love the build.

[KCStudly]

A rubber membrane would make a more faceted surface than the aluminum scales. The difference wouldn't be much, but it would still leave voids between the two. Just saying, moisture buildup or space for condensation might be a concern. The advantage of the commercial spray foam option would not be fully realized unless it completely backs up the outer skin, at least IMO.

[dave campbell]

hey all-----still plugging away here. not posting everyday because it's the grubby part of the build---boring and uncreative but necessary.

possibly one of the dumbest things i've done !! a little dude on my shoulder is saying "you idiot--should'a sold it !"
ah well-- live and not learn. it will make a most excellent motorcycle garage
holy ____ that was a noisy operation. i stood inside, set my eye on the horizon, and lay waste to the four directions with a sawzall !

vladimir traileroff.JPG (21.88 KiB) Viewed 1687 times

zipped all the crud off and wire brushed and methyl hydrated and painted with tremclad. i'll be replacing the back end after the new buggy goes on top....

topside prepped.JPG (72.88 KiB) Viewed 1687 times

cheers !

[dave campbell]

after much contemplation i will be avoiding the foam layer under the aluminum. it has been suggested that i attach the aluminum directly to the cage, by several people, and that is what my plan is now. makes perfect sense to do it that way. i will do my best to eliminate galvinic corrosion and ghosting of the cage through to the surface by using foam shims, then insulate from the inside. .

cut a few dozen tabs today to help hold the floor down----

tabs tabs tabs.JPG (92.72 KiB) Viewed 1686 times

i plan on about 6 pieces of flooring so i can recycle that sacrificial bulkhead plywood from earlier in the build
so these tabs will come in handy. in the case of floor rot it MAY be less work later if i have more pieces of floor ?----

tabs tabs tabs2.JPG (71 KiB) Viewed 1686 times

[dave campbell]

because i had to wait for the neighbour to go out before i could make my noise this morning---i thought i would give a stab at the wee 4" portal windows that we want along the roof.
they will be aluminum, and rife with personality (imperfections)

step 1 : plexi and placement

lightwell1.JPG (58.52 KiB) Viewed 1686 times

step 2 : foam porthole mock-up

foam porthole mockup.JPG (66.28 KiB) Viewed 1686 times

step 3: silicone mold. darn foam is all floaty !

silicone mold.JPG (78.39 KiB) Viewed 1686 times

[dave campbell]

porthole continued-----

step 4 : hot wax

hot wax.JPG (54.67 KiB) Viewed 1683 times

step 5 : whole lotta love

shaverman.JPG (53.06 KiB) Viewed 1683 times

step 6: ready for the sand mold soon (maybe some rivet detail ?)
the four tabs are there so i can bolt these on from the inside....

wax porthole.JPG (63.42 KiB) Viewed 1683 times

[Caveman1970]

WOW!
Pouring your own porthole...I wish you were my neighbor!

[kudzu]

This build is going to be amazing. Love the shape.

...I wish you were my neighbor!

Does anyone else hear Mr Rogers singing?

[OP827]

.... i will do my best to eliminate galvinic corrosion and ghosting of the cage through to the surface by using foam shims, then insulate from the inside....

There is a lot of information available on how to prevent galvanic corrosion and it is achievable when knowledge is on our side.

To start and get some ideas I looked at https://en.wikipedia.org/wiki/Galvanic_corrosion and https://www.fastenal.com/content/feds/pdf/Article%20-%20Corrosion.pdf

Other people on this forum may have an expert knowledge of the subject and hopefully will chime in to help.

[dave campbell]

hey thank you OP827 i shall be sure to look that up !

[dave campbell]

kudzu and caveman1970 thanks for the kind words

latest update from campbell's machine shop----removed the axle and springs yesterday, so this afternoon i took the angle grinders and brushes to them. also yesterday i zapped on the rearmost bar of the chassis, and painted it today along with a couple nice coats of tremclad gloss black rust paint. methyl hydrate to everything before paint.
new bolts to hold the leaf springs to the chassis---as the old ones were in rough shape. i actually sheared the threaded section of one of them right off. all others i restored---wire wheel, re-tapped etc....

here's the pics-----

axel and leaf.JPG (32.28 KiB) Viewed 1613 times

silver springs.JPG (59.03 KiB) Viewed 1613 times

black axel.JPG (48.31 KiB) Viewed 1613 times

cheer s all

[dave campbell]

a few more shots---

the base of the new unit was supposed to have one of the cross-bars sitting on the rearmost bar of the donor chassis (which was 5" front to back, 60 side to side) but that bar was rotten and (not thinking) i replaced it with 2X3 stock---to match the rest of the chassis.
thus the extra tabs on the back

new rear bar.JPG (61.37 KiB) Viewed 1610 times

tried lube, heat and brute force. triple trouble

man of steel.JPG (52.9 KiB) Viewed 1610 times

these bolts were 3.50 apiece--- and the girl at the desk was also going to charge me 3.50 each for the nuts as well ! i saw her write it down and total it so....
me------"i'll just by those elsewhere thanks. they should be 50, MAYBE 85 cents at the most "
her----"well that's what it says on the box...."
me (goes to look) "holy cr__ they ARE 3.50 each for a friggin' nut..."
other girl-----"i'll go ask the boss because that seems weird (exits room)

and so on this goes between 3 of us and the mystery boss for a few minutes until the second girl comes back and says----"hey says to give them to you as a combo for 3.75 for a nut and bolt"

meanwhile i had already paid for the other stuff and the first girl wasn't interested in another transaction so i got them for free !

new gear.JPG (59.04 KiB) Viewed 1610 times

[OP827]

Electric brakes are a good thing especially when the trailer is a little heavier..
Just a thought, do you plan to have them?