Finally..... getting started on the tear drop. After several delays for one reason or another..
The making of my Reusable Tear drop profile template: 11/6/17 Template for my project will need to be 4”-6” high X 11'-0'' long.
Now, how to get that? I wanted to share this as I make this one. Maybe it will help someone else. I have used this process before in several different applications. It works great.
Remember if you are making one of these like I am for future use. It doesn't have to be pretty. It has to be durable to use over and over if needed. When finished drill a couple holes in it and hang it on a wall out of the way somewhere. Always ready for the next teardrop.
Start with 2 sheets of 1/4” inch sande plywood. Can be luan, pine, sande. What ever fits your wallet.
Materials and tools used. Wood glue, box of wax paper. Utility knife. 1 ea roll of 1-7/8” x 150' white mesh joint tape with adhesive (found in sheetrock area of local box store), Plastic putty knives. The knives I chose came in a combo kit including 1 ea, 1.5”, 3” 5”. 2 ea wood clamps or C-clamps. I use a porter cable trim router with a 1/4” straight bit (no bearing).
Not having the use of a garage or workshop big enough to work. I set everything up on my carport. Using my teardrop trailer as a workbench. I laid a couple 3/4” sheets of plywood on the trailer for a work platform.
The first cut will be a 6”wide x 8' long strip off the edge of 1/4” sheet of ply. So I measured back from the edge 6” then added the measure ment from my router base to the out edge of the router bit. This measurement will very depending on your router and bit used.
Laying the other sheet of 1/4” ply on top of the one to be cut. I align the edge of it with the measurement marks. This is now my 8' straight edge. Clamp it down on both ends. Run the router base against the edge and make the cut. (Don't worry about the edge not being perfect for this process. It will help the glue hold better. (this is not a finished part to stain and finish).
6" strip next to panel where it will be glued..
Unrolled approximate 8” length of wax paper and cut it. Raised up the edge of plywood to be glued and slid the wax paper under the edge halfway. (this keeps excess glue from going through the joint and gluing to board underneath).
Run a bead of glue on the edge of the 6” strip and lay the 6” strip on the wax paper, gluing edges together. Using the mesh tape, I gently apply pressure to the side of 6” strip with my leg to hold it against the other sheet (Caution: do not slide leg against edge, Can we say “Splinter”?).
I apply the tape sticky side down over the seam (note seam is centered under the tape) apply tape the full length. After I applied the tape, I used the 1-1/2” putty knife to smooth out the tape.
I run a healthy bead of glue on the visible wood seam. (as in picture).
Spreading the glue with the 3” putty knife. Working the glue into the seam and mesh tape.
Careful not to apply too much pressure as to pull the tape loose. Just smooth it out good. I let glue sit till it ways longer). (clamp and let dry. Humidity in my area makes glue drying time always longer When it was tacky, applied two more lengths of mesh tape. Starting one with the edge of it in the center of the first strip. Then the other with the edge matching the strip before. Now I have one strip applied, with two more strips side beside over the first. Then apply glue as I did the first strip and smooth out with the 5” putty knife.
Satisfied with the gluing I now cover with wax paper.
Lay a 2” x 4” over the seam and weight down with a gallon of glue and water and 12 packs of cokes (They were handy) as in picture. I write the time next to the glue joint so I know when I finished the process. Had something else to do while it was drying. Can't rush the drying.
Next morning 11/7/17Up and ready to go, first cup of coffee gone and working on second.
Stepped out on carport. Wow, great news to start the morning with. All 12 packs of cokes still where I left them. Amazing.. with all the kids in this neighborhood.
Removed all weights and wax paper. Checked to see it was dry.
Looks good.
(Knew the wax paper also delays drying time, takes longer for the air to get to the glue). Worth the time though. Remembering, this will last a long time for future use. Gently flipped over the panel and repeated the same process to this side.
Note: If you are joining two pieces of 1/4” ply together for a finished skin, you can use this same porcess to join the seams together. Just use the process on the back side not the front. You can sand it lightly after drying).
I use titebond II premium glue, for panels I plan on using outside. It's water resistant, interior or exterior glue, and it's water clean-up.
Coming next:Adding the 1/4” x 3'-0" x 54” panel the the end of my template.
Good ole Texas weather hit us. Rain, wind and cold weather. So just when i thought everything would come to a halt. Not able to work on the carport. A friend came to my rescue and offered up his pole building behind his house. So this project has moved inside. Thankfully