OK, Stomperxj, I'll do it your way, that makes sense. Then all I have to do is edit to update today's date. Thanks!
Tom, Thanks for letting me know someone is following how I do things. I'm sure there are many other ways to accomplish the same things, these are just the ways I've found that work for me. Hopefully it will help others.
Alright here are a few things I just finished .
The dreaded Galley hatch! First off I am using a hinge I get from So-Cal Teardrops. It is 20 bucks a foot, which I do not like. It's expensive. But I used it on my first build and it works well and I love it. I work completely alone. So not having anyone around to ask, "hey can you hold this" doesn't happen. This hinge allows me to put the galley on and off as I need to. So for finishing and fitting everything it's a big plus.
Here is what it looks like.
The hinge is a ratchet style. You slide off the cover and the hinge separates. Very easy to take the galley off and on. Here are the stops that keep everything in place.
The first thing I did was make 1 rib that matches my side profile. I allowed for the thickness of the metal and gasket material. After I make one perfect pattern, I needed 6 more. I traced the perfect one onto my 3/4" plywood.
Then I band sawed between my drawn out ribs. You could use a sabre/jig saw if you have one. Really doesn't matter the cuts are not accurate.
Now I have my 6 other ribs, all over sized.
Now I take my first perfect pattern and screw it to my over sized rib. Then I use my router with a 1/2" straight bit with a bearing on the bottom. Flip the screwed together pieces over with the pattern piece on the bottom. Run the bit around following the pattern to duplicate another perfect rib. I use a router mat. Really helps hold the work in place and helps save fingers! Really cheap and great for sanding on as well.
After I get my 6 other ribs made. I wanted to make a mock up of the hatch. Since my hinge comes apart I just screwed 2 ribs to a short cross piece to make a mini hatch. What I wanted to do was fit the lift struts.
Then I made a pattern piece out of 3/4" plywood that matches the tears profile of the side. Two C-clamps hold it in place. Now I am able to measure and screw the strut in place without worrying about messing up the hatch and the galley side. There was a thread on here from Grant I believe that showed where to place everything. I am down about 4.5" from the top of the hatch, and about 17.5" to the bottom. Your results may very depending on the length of your struts. But It really does not matter since you can make a million holes if you want. It will never show. Then lift the hatch and check for head room.
Now that I have my placement right, I run some 1" screws into the bottom strut bracket. This makes a hole in the galley side to mark where the bracket goes "for real".
After this is done, take everything apart. Take the pattern for the strut bracket and flip it over and clamp it to the other side of the galley. Screw some 1" screws into the holes left from side A and now side B is a mirror image. When the hatch is done the struts are already marked for install.
Next I assembled my hatch. Used pocket screws (KREG, great tool !) to put it together. Next I installed all the blocking for the hatch lock and the tail lights and License plate light/bracket.
Here is the finished hatch just sitting in the opening.
I then started putting a few of the cabinets in place. I have moved these all around the shop for weeks. Nice to get them out of my way and where they belong.
Well that is where I am so far.
by stomperxj » Tue Aug 24, 2010 10:55 pm 
