the jelly belly build

[del]

Andrew we call those electric radiant heaters, electric heaters. Does that mean we are lazy? My idea on the window is cut the skin round. Then cut the window square and put it on the inside, clamped in with the inside backing ring. sealer between the window and outer skin. small bolts clamping the whole thing together.
Todays progress.

I will have to sink the ice chest into the counter so I can get in it (I am vertically challenged). Other than that it is shaping up quite nicely.

del

[angib]

My idea on the window is cut the skin round. Then cut the window square and put it on the inside, clamped in with the inside backing ring. sealer between the window and outer skin. small bolts clamping the whole thing together.

That sounds like it will work fine and with only 1/8" skin, the recessing of the window won't be noticeable. You might not need the backing ring.

The one thing to watch out for is the recess formed by cutting the skin - water will pool in there and it's right on the cut edge of the plywood which is very susceptible to soaking in water. You either need to soak epoxy into the end grain of the cut, or apply lots and lots of coats of paint/varnish.

Andrew

[Laredo]

Angib,
what about a window mounted proud instead of inside? Would that leak more/less / differently?

[bobhenry]

I have purchased 6 4' x 10'4" sheets of 1/4" bronze lexan. I am wrapping the 5x10 tear roof and sides in it. These were salvaged commercial sky lights. Despite being 1/4" thick they almost formed around the 2'-6" radius of the nose of my tear. Your sides do not appear to be even twice that. What are they 5' maybe 6' radius. I lost my nerve to force it and am training it on sunny days by drawing them down with a ratchet strap. I have previously used a heat gun to form a pair of air deflector wings for my motorcycle. ( The old one were thinner and were damaged). Andrew was right it took me 3 trys to bend the 15 degree returns on each side. Too hot and it turned white with bubbles not enough heat and it would not bend. How about a solar oven they get to 250 - 300 degrees. A large appliance cardboard box, some black paint and a good size discarded window glass to let the sun into the oven and a form to rest the lexan over like a cardboard barrell. This Lexan is amazing stuff I really think this idea is worth a try.

P.S. Once it's formed go to the auto glass shop and get the gasket profile they use in the rear windows of the pickups and install with it. no leaks no water infiltration.

[angib]

what about a window mounted proud instead of inside? Would that leak more/less / differently?

I don't think either way will leak - it's allowing the exposed edge of cut plywood to sit in a puddle of water that worries me - the end grain will soak up water and then it will rot.

Putting the plastic on the outside cures the problem - now it's the cut edge of the plastic that's exposed and that doesn't suffer from the water at all.

But it won't look too nice.....

Andrew

[del]

Todays progress built a shelf for my ice chest.


When I put the counter top on the hole for the ice chest will limit its movement. If a slightly bigger ice chest is ever used, all that is needed is trim the counter (pretty tricky). No I do not plan to put ply on my shelf, I figure when water is spilled it will go down and out the drain that needs to put in the lower floor.
Today I also cut out four spars for the tail. Tomorrow I will clamp them together, true them up with a sander, and hopefully install them. Pics tomorrow.

del

[doug hodder]

I have purchased 6 4' x 10'4" sheets of 1/4" bronze lexan. I am wrapping the 5x10 tear roof and sides in it.

Bob...lexan will tend to expand and contract through the daily heat cycles, more than an acrylic like plex, especially in larger pieces like you are wanting to use. you might want to check out GE's site about how much you can expect. I know in the sign industry, we had to hang the poly/lexan sign faces with a hanging bar to allow the face to do it's thing. Float the pieces with a retainer.. Just a thought...Doug

And Del...it really looks like you are coming along well...still watching...Doug

[del]

Doug my windows being 20" in diameter, and being lexan, do I need to worry about expansion and contraction? I know that I am not working on the windows right now, but I am worried about them, so if any one has a simple solution I will be most grateful.
Today I installed the drains in the rear compartment (tail section). Next I sanded the four spars and installed them.



del

[doug hodder]

Del...I wouldn't sweat the 20" dia windows...we only had issues with the larger material in sign faces and when covered with vinyl would take on more heat than a clear or smoked piece....I would think that the expansion issue would be minimal in your situation. I would however use an adheseive/sealant that allows for some slight movement...like a silicone that can move with the material that it is contact with...make sure that your outer edge of the ply cutout is very well sealed however, it won't cause a problem with the window, but will wick in water and cause exterior issues on the finish if not sealed up....I spent a lot of time taking care of that on the Rocketear, and I got in a ton of rain and water on the trip to Minden, no problems there.... Doug

[del]

Andrew and Doug my plan for sealing the ply around the window, is to seal it with resin, then paint. If I bevel the ply water will have less of a chance to puddle there. Cosmetically the part I do not like is the head of the bolts on the outside, but that seems like the simplest solution.
Progress I started to tie the spars together.


del

[khutson]

All those curves just boggle my mind!

It's looking great and following your build everyday. Just all those curves make me dizzy, I fretted over what curves I've had to deal with and just can't imagine all those. Most excellent for sure!

Ken

[del]

Today I added one more brace that goes to the back point of the trailer. Now I could measure how long the body is (have not done this yet). man is it ever long. I do have some bad news though, the pics I took did not turn out, so I hope to get by on a rain check tonight.

del

[del]

Here are the pics that are from yesterdays progress. I hope this makes my picture bubble oil level.


Man is this thing long. The metal piece is just temporary, so though it is heavy it will not add to the final product.

del

[Classic Finn]

That is a Unique Build ... All the curves and such just amaze me as well.. You must have a lot of Patience on this project..however it is looking fantastic...

Classic Finn

[Tear Les]

Here are the pics that are from yesterdays progress. I hope this makes my picture bubble oil level.


Man is this thing long. The metal piece is just temporary, so though it is heavy it will not add to the final product.

del

Man Del! You gotta be careful with those picture; the last couple just about short-circuited my brain!

I'm glad you explained in the text that the metal tube wasn't stayin 'cause I sure couldn't figure out how the heck the hitch was going to work there! [Gooseneck trailer maybe?]