CapeBuild Build Journal

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

Re: CapeBuild Build Journal

Postby Capebuild » Wed Oct 13, 2021 5:04 pm

10.13.2021


Got the headliner installed today. Like wrestling an alligator getting the ply to bend around that curve in the front. But my able body assistant and I had success. A milestone! If I had to do it again I think I might have wetted the curved area with boiling water and towels. But, it's done and glad to have that behind me. Also got a couple of spars installed... well just another oak piece installed where the hurricane hinge will mount and then a 5/4 poplar spar just off from that. The opening in the headliner is kind of an access area to wire in some electrical stuff. It will get covered with the insulation and outer ceiling. There's also an access panel on the inside for servicing it in case I need to get in there.
Thanks.

John
Attachments
trailer 1.jpg
trailer 1.jpg (267.2 KiB) Viewed 772 times
trailer 3.jpg
trailer 3.jpg (322.44 KiB) Viewed 772 times
trailer 2.jpg
trailer 2.jpg (121.84 KiB) Viewed 772 times
"Success can be defined as moving from failure to failure without loss of enthusiasm".... Churchill

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Re: CapeBuild Build Journal

Postby MickinOz » Wed Oct 13, 2021 5:26 pm

The workmanship looks outstanding, mate. Profile is killer.
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Re: CapeBuild Build Journal

Postby western traveler » Wed Oct 13, 2021 6:15 pm

How sweet was that to finally sit inside and experience the space you are have created! Nice…
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Re: CapeBuild Build Journal

Postby Capebuild » Thu Oct 14, 2021 5:06 am

Thank you, Mick and Ralph for your encouraging words. I appreciate the comments :)

Attached are a couple of additional images I meant to post yesterday after installing the headliner.
headliner installed.jpg
headliner installed.jpg (378.96 KiB) Viewed 730 times

interior.jpg
interior.jpg (233.98 KiB) Viewed 730 times


Today I'll be installing the spars. Attached is an image of my "go by"... the rear opening is for the fan, the middle opening is for a picture window and the front opening is for storage.
sidewall-ceiling setup_10.13.21.jpg
sidewall-ceiling setup_10.13.21.jpg (241.14 KiB) Viewed 730 times


Thanks

John
"Success can be defined as moving from failure to failure without loss of enthusiasm".... Churchill

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Re: CapeBuild Build Journal

Postby TimC » Thu Oct 14, 2021 8:12 am

Beautiful John! You are a real Craftsman...
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Re: CapeBuild Build Journal

Postby Capebuild » Mon Oct 18, 2021 4:22 pm

TimC wrote:Beautiful John! You are a real Craftsman...

Thanks so much for your nice comment, Tim. Appreciate it!

I've gotten most of the spars installed. Just need to install the blocking up on the inside 2 wall edges and then can start to finalize the wiring.

I used a piece of plywood that had a straight edge to check that all the surfaces of the spars were on the same plane especially in places like the picture window, fan and up front storage area where there's four spars in a row.

John
Attachments
spar 1.jpg
spar 1.jpg (258.48 KiB) Viewed 677 times
spar 2.jpg
spar 2.jpg (241.44 KiB) Viewed 677 times
spar 3.jpg
spar 3.jpg (248.41 KiB) Viewed 677 times
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Re: CapeBuild Build Journal

Postby Capebuild » Wed Oct 20, 2021 5:58 pm

10.20.21

Finished installing the spars today along with the blocking. Painted urethane varnish onto what will be the concealed inner surfaces of ceiling.
Will next start to do the final wiring.

John
Attachments
final spar.jpg
final spar.jpg (168.04 KiB) Viewed 643 times
spar final 2.jpg
spar final 2.jpg (181.82 KiB) Viewed 643 times
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Re: CapeBuild Build Journal

Postby Capebuild » Mon Oct 25, 2021 3:28 pm

10.25.2021

Another milestone.... installed enough wiring to test most of the circuits. All interior cabin lights installed, even the dimmer for the 2 main puck lighting works. The dimmer is nice in that the puck lights are bright. Porch lights are working.... as well as the 3 - 12 volt outlets and the 3 USB outlets.
Surprising how much wire is used. I had started with 100 feet of black and a 100 of red. Used all of that and then ordered another 75 feet of each. Used maybe a third of that so far....although pretty much finished with the trailer wiring connected to the house battery. For some of the connections I used those Wago connectors. Those things are great. They worked out really well. I used the model that accepts 5 wires. On one circuit with a number of fixtures I used a jumper from one Wago to another for another 4 connections. Easy to use and mounted them using VHB tape.
Next to hook up the lighting that will run from the tow vehicle (marker lights, tail lights, etc.) Also need to cut out for the fan and just make sure that works.

John
Attachments
IMG_5898.JPG
IMG_5898.JPG (92.2 KiB) Viewed 584 times
IMG_5900.JPG
IMG_5900.JPG (123.67 KiB) Viewed 584 times
IMG_5894.JPG
IMG_5894.JPG (118.93 KiB) Viewed 584 times
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Re: CapeBuild Build Journal

Postby Capebuild » Thu Oct 28, 2021 5:46 pm

10.28.21

Cut out the front large picture window today (the star gazer). Adding some Baltic Birch facing pieces on the interior frame surfaces and then will install an interior frame around all that. Waiting for some ring connectors to arrive and the tail lights, 3rd brake light and license plate holder (illuminated) and will then wire up the lights powered from the tow vehicle. I haven't yet ordered the license plate holder with light so if anyone has any suggestions or one that they like, please let me know. I suppose they all seem pretty generic....so it's like "just pick one" :)

Tomorrow picking up 5 sheets of clear anodized aluminum for skinning the trailer along with a 4x8 sheet of polycarbonate for the windows. I wish I had asked the supplier for some specs on the aluminum prior to driving to them....so I can get a better idea of what it looks like... .but guess I'll find out tomorrow when I get to the distributor.
John
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window opening.jpg
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Re: CapeBuild Build Journal

Postby featherliteCT1 » Fri Oct 29, 2021 5:56 pm

As I watch your build, I find myself smiling with admiration for your work! :applause:
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Re: CapeBuild Build Journal

Postby Capebuild » Mon Nov 01, 2021 1:33 pm

Nov 1, 2021

featherliteCT1 wrote:As I watch your build, I find myself smiling with admiration for your work!

Hi FeatherliteCT1. Thank you very much for your nice comment. I appreciate your saying that!

Got the framework for the picture window installed along with the interior frame molding where a pull down blind of some sort will reside between that frame and the window.
Made one frame and needed to change the layout a bit, made another (luckily had an extra sheet of 1/4 inch BB) and that worked well.

Hoping to get a start on the tow vehicle wiring of the lights that are on the trailer (marker, stop, tail lights, etc). Once that is complete I should be
able to start insulating the roof.

Also... on Friday my wife and I drove up to the Boston area and picked up the aluminum for the siding and also a sheet of polycarbonate for the windows.
Kind of a hairy ride home having fit the 6 sheets of 4x10' aluminum in our 4 x 6' utility trailer (took the local roads for most of the trip)... but made it. Made me realize
I need an anti rattle hardware on the connection between our hitch the Subaru receiver.

John
Attachments
front window interior.jpg
front window interior.jpg (222.96 KiB) Viewed 457 times
front window exterior.jpg
front window exterior.jpg (185.78 KiB) Viewed 457 times
front window exterior 3.jpg
front window exterior 3.jpg (191.79 KiB) Viewed 457 times
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Re: CapeBuild Build Journal

Postby Capebuild » Thu Nov 04, 2021 3:21 pm

November 4, 2021

Started finalizing the wiring from the tow vehicle until I ran out of wire. More on the way.
Cut out the front opening where a storage area will be (accessible from the interior) and started working on the outside construction to close that in.

John
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IMG_5922.JPG
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Re: CapeBuild Build Journal

Postby Capebuild » Sun Nov 07, 2021 4:45 pm

11.7.21

Working on the front bump out storage unit. Integrating the roll pans into that..taking a bit of thought to get all that to mesh and "weaving" it all around the chassis framing :thinking:

The board on the bottom shimmed up on the cinder blocks runs the width of the trailer and is making sure the two side wall's bottoms and the 2 wall bottoms of the bump out are on the same plane.
Attachments
IMG_5925.JPG
IMG_5925.JPG (114.39 KiB) Viewed 377 times
IMG_5926.JPG
IMG_5926.JPG (133.84 KiB) Viewed 377 times
IMG_5930.JPG
IMG_5930.JPG (120.21 KiB) Viewed 377 times
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Re: CapeBuild Build Journal

Postby Capebuild » Tue Nov 09, 2021 5:07 pm

11.9.21

Working on the out side front roll pans (left and right). They will tie into the front storage bump out which also has its own roll pans. I simplified the design of those after looking at how others have done this. Some pics attached. The challenging part is getting them to mesh with the chassis frame members, which is one reason I simplified the pans that are part of the bump out. Will work on those tomorrow.

John
Attachments
IMG_5939.JPG
IMG_5939.JPG (128.03 KiB) Viewed 346 times
IMG_5938.JPG
IMG_5938.JPG (92.04 KiB) Viewed 346 times
IMG_5936.JPG
IMG_5936.JPG (90.48 KiB) Viewed 346 times
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Re: CapeBuild Build Journal

Postby halfdome, Danny » Tue Nov 09, 2021 6:48 pm

Well John, you nailed it, nice roll pan structure's.
The challenging part will be to get the aluminum to go smoothly over your build up.
I found that's a vulnerable area for debris coming off the TV tires.
I put that peal and stick rino liner over that area and it gives a nice offset look.
:D Danny
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