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[ghcoe]

George, that’s BRILLIANT !!!

Thanks.

[ghcoe]

Test fit of the galley sides showed that the channels did line up well.

Left side galley

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Right side galley

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Outer shot of galley

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[ghcoe]

Shelves made form left over foam from the roof panel. So far I have not had much foam scrap.

Just did a test fit today before gluing it all up. Maybe tomorrow, still a few things to think about before I make it solid...

Lower galley shelf

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[GPW]

Really NICE how everything fits and locks together ...

[AlgoDan]

Dang that Foamie looks sweet, nice build you have going.

[ghcoe]

Really NICE how everything fits and locks together ...

Thanks! Really makes everything strong too. It is building in strength and is a lot easier than I was anticipating with the foam.

I am having a lot of fun with the hot wire. The shelves in back were gravity feed hot wired. Starting to get a technique down now.

When I was planning on making a TD years ago I was planning on doing the dado build technique with ply or OSB. I think it makes it look cleaner and makes it stronger.

[GPW]

Strong indeed !! You’ll be surprised of just the strength of the foam box , and when you get it skinned , it’s crazy Strong !!! ... yet Light !!!

Good joinery is always appreciated , whether with wood foam or metal ... I use those dados for my amp and speaker cabinet joinery ... locks everything together ... and Straight too ...

[ghcoe]

Dang that Foamie looks sweet, nice build you have going.

Thanks.

[ghcoe]

Made some spacers for the galley frame rails today.

Galley spacers

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Found some trim I liked for the rear galley edge. Not sure if it is going to work out the way I want it to yet or not, but hey it looks good for now.

Spacers and rear trim

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Got the last of the frame rails in place and lowered the body back down onto the floor.

Galley frame rails

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[ghcoe]

Next I test fitted the galley sides and cut the notch out for the sub roof.

Galley side notch

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Then made sure stuff fit ok.

Test fit camping stuff

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And test fitted the shelf trim.

Shelf trim

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Another weekend done.....

[GPW]

Good weekend’s work !!!

[wagondude]

Your making great progress. I like your gravity feed hot wire idea.

[ghcoe]

Not much happened this weekend. Tried to do the front radius with 1" foam. Looked ok but did not like the way it was bowing in in the middle. Then I realized I was putting a lot of stress on the whole structure with my clamps. Decided I needed to try to kerf to release the strain and made one cut about 1/2 inch into the foam. I tried it under stress because I had already glued it. Mistake! Sounded like a shotgun blast and split right in two.

Well live and learn. Going to maybe try next week kerfing a 2" think panel and see what happens.

[GPW]

George, tricks that work to bend 1” foam around a curve ... Some folks use packing tape bands on the outside to relieve the tension loads on the outer foam surface when bending ... Heating the foam to ~ 190F works too and if you do it right , the foam will adapt to and retain that shape when cooled (foam forming) ... no springback ...
If you plan on doing the kerf method on 2” foam , be sure to read the Kerf thread above ^ and do the math .... that way when the foam is bent the kerfs close together and present a clean solid surface inside ... no big gaps showing... I’ve got a LOT of kerfing to do for the FoamStream ( 10’ long kerf cuts) ... Got the calculations all worked out ... should work fine , even on my 3.5” thick beadboad foam ...

[ghcoe]

Thanks GPW. I read that. I think the problem was that I started the kerf at the bottom where all the stress was at. Thinking about it now I think I should of started at the top or let the foam relax and started over. I still like the idea of two sheets of 1" with the kerfs towards the center. That would make for less work filling grooves, and sanding.

I just got done making a hot wire jig that will cut five 3/4" inch deep grooves at a time. Gave it a test on a piece of scrap and I think it is going to work great. These jigs take a bit of time to set up, but are easy to do and sure speed things up in the long run.......

I have a tight radius on the back that I am a bit concerned about now. I have a couple ideas for that too.....