Lifting roof XPStream - making improvements

[KCStudly]

Merry Christmas all around!

[OP827]

And as a Christmas gift to myself I did this clamps organizer, with a space to spare for more clamps

[Vedette]

Nice Clamps!
I too have a simple clamp bar in my shop that helps to keep all of those pesky clamps under control....when not in use!
Good Roads
Brian & Sandi

[OP827]

Thanks Brian.
Today's update -
As previously mentioned, to fix the roof I decided to cut the roof panel across in two parts and flip the front section 180 degrees as it would create a nice, light spherical front curvature and, in fact, it did.
After stiffeners were added in the front section and fully cured, I had to figure out how to put this all back together.
I have dreaded this big glue up and planned it for how I would, while working alone, make sure that the two big sections align properly. I have come up with this ridiculous apparatus shown on the photos below. It consists of clamps, cauls and wedges, packing tape in many places for epoxy separation, and foam block supports.
And today I did this major glue up. The seam is reinforced with thickened epoxy, fiberglass strip on top, pine strip stiffener and fiberglass on bottom and all this sandwich is pressed together with cauls, wedges, clamps.
It should require very little sanding to clean things up, as all squeezed out epoxy was carefully removed with a taping knife. Took me about 3 hours to put this contraption together, thankfully epoxy allows that.
Now need to keep my garage temperature at 70 for a couple days at least. Quite happy with the result.
Cheers!

[dales133]

Love watching you work the glass.
I hear you on working out how to do things alone,ive built 90%of mine on my own and it realy adds to the challenge but teaches you alot of resiliance.
Ive realised getting off my arse,on my own.instead of over thinking things gets almost anything done

[KCStudly]

Pure will, perseverance and clever application of some mechanical elements (screw clamps and wedges) gets it done in style!

Nice work.

I hope the low profile of the slats/ribs is enough to give the stiffness you are looking for.

[OP827]

Thank you guys Dale and KC for kind words of support. KC, as far as deflections I am not concerned, the structure is rigid.

[Atomic77]

Very impressive Oleg! I'm going i see this thing in person some day!

[OP827]

Very impressive Oleg! I'm going i see this thing in person some day!

Thanks Michael, yes, I have a feeling that you are going to see this thing in person.

[OP827]

The above mentioned major glue up of front and back roof panels was a success, it looks like the panel was never cut apart.
Will do a minor cleanup sanding after all stiffeners are installed.


Two more stiffeners were added for total of 5 so far, this could be enough for fixing the roof curvature, will see, but I am considering maybe I could add the ribs for all internal roof surface like it is in front, just for additional reinforcement and consistent look, but at the same time the roof is already sufficiently rigid and I do like a clean look of internal roof more, it feels more spacious and clean. Maybe I should mention again that the sag I fixed was not caused by the snow load, it is due to wrong sequence of lamination. Next time I will complete laminating the roof outside surface first and then do the inside while controlling the across curvature better than I did the first time, lesson learned.


I am actually quite surprised and happy about how big and spacious it feels inside the trailer when its roof is up. It is like a total transformation of space. I lowered the trailer frame very close to floor and I can now completely lift the roof inside garage without removing the garage door opener motor, I simply unplugged it for good to avoid any accidental damage.

[KCStudly]

Excellent!

[OP827]

Gel coat coating over cured epoxy, it does work according to West Systems - http://epoxyworks.com/index.php/thats-a-fact/#more-2487

[dales133]

So your planing on a gelcoat over glass finnish over the whole thing?

[OP827]

So your planing on a gelcoat over glass finnish over the whole thing?

I don't know yet, I still have lots of time to think about it.

[Bluebunny]

We're so excited to see such wonderful work and good progress! I must admit I like the size and roominess. I'm afraid my 5x8 standie will be a bit cramped. I thought about pushing my sides 3 or 4 inches proud of the frame width, but decided not to. My 1000 lb budget won't allow, alas...

When I get mine finished I'm pulling it up your way to see your wonderous contraption!