Lifting roof XPStream - making improvements

[OP827]

An option to a full length weld would be to stitch weld it, say 1 inch long beads every 3 or 4 inches, then you could use paintable seam sealer on it to seal it up.

Thanks KC. I'll do just that

[OP827]

The step is finished and coated, paint is drying in cool albertan afternoon sun, waiting to be welded to the frame.

[OP827]

Tonight i welded the step in place. "Milestep" achieved !

[OP827]

I need to have two identical wall panels in front of the trailer with curved foam so I made these custom brackets/clamps out of scraps for their glueups. The photos show dry fit, quite happy with them. They will just "click in place after I put glue in the kerfs. Looks like a wing section . I am thinking to use Great Stuff for the kerfs as a glue, it should make for a strong curved panel and fill the kerfs good.
My progress is quite slow, I only have an hour or so a day to work on the trailer so far..

[KCStudly]

Neat!

[OP827]

Thanks KC.

I went ahead and glued up first panel this afternoon using this new method. Will keep it clamped at least until tomorrow, hope it will be enough time for foam glue to set w/o issues

Scotch tape to reduce sanding the foam after glueup


Clamped or rather "clicked" in place, the fastest clamps on earth


Nice and straight


Now the part will have to wait for the glue to cure. ... OK, but only one cup and back to other things to do.

[OP827]

It is impressive how easy the scotch and foam squeeze out pealed off and left NOTHING for sanding, WOW

Is that a good candidate for FOAMIES FORUM separate article or even maybe a sticky ?
I did not see such packing tape trick used here before, but i did not read that BIG foamies thread yet.

[KCStudly]

Looks like packing tape is a real winner! I used blue tape on butt joints but it was nowhere near as effective.

Looks like you have to use a bunch of tape, tho. Did you put it on in the flat and slit away at the kerf's or... ?

[OP827]

I wish I put the tape on foam before the kerf were cut (next time I'll do that), but this idea with packing tape came later.

So to make it work I first put the panel in the clapms so that the kerfs will close and then put the tape. Then cut the tape along the kerfs with sharp blade. Then removed the clamps, put glue in the kerfs, clamped back, waited for glue to cure, pealed off the tape, did a photo .

As for hjow much tape used, I would say not much and it is well worth it. I spent so much time sanding and busted sand paper last time I di this glueup with other panel, so the tape is a way to go and it is more economical overall for me.

[OP827]

Second curved panel glued up and clamped this morning, easy and fast, thanks to below described trick.

Previously it was difficult for me to put Great Stuff inside each kerf in a clean way and right amount.. suspect I am not alone as all I heard here is that GS is very messy.

Then I found that if i take of the plastic tube and run this can tip inside the groove, this difficult process becomes a very easy and FAST which is more important on a bigger amount of kerfs to fill, the kerfs are now fully filled with GS, making for a stronger panel and with a right amount of squeeze out, no mess. groove on! I like foam, it's fun

[OP827]

For the first time put first two wall panels together today, just a dry fit for now. The photo does not do it justice. The curve panel fits to next wall panel flawlessly. It feels so great to finaly see the ideas starting to come together. This wall panel with plywood edge and dowel works great, we are "masterbuilders, everything is awesome!"

[OP827]

Here is a better view of wall panels detail. No sanding was needed for the curved wall section.

[KCStudly]

Nice. It's always better when it turns out like the plan.

[OP827]

Did a raw fit of walls today to see the actual trailer size and try for size to sleep across and enter and exit for door height.

A little unusual to have lower door, but seems to work ok. The door will be about 62 inches from step to top in folded roof position. I think I can leave it like that w/o further thinking of additional door top extention beiing part of folding side wall

Is 62 inches entrance height good enough??

Sleeping across works good for my height, no worries there

[Bluebunny]

Looking great! Following with interest! Do the images below remain your intent? The gap below the roof filled with the rigid folding panels? Bravo!