#1

[pohukai]

The technique you're used is fantastic. If I do another, this is the way I'll do it. What do you plan to use to cover both the inside and outside of the foam?

[ghcoe]

The technique you're used is fantastic. If I do another, this is the way I'll do it. What do you plan to use to cover both the inside and outside of the foam?

Thanks for the complement, I just hope it all turns out true in the end result. I am pleased with how it is going together so far, but I am waiting for a
Might I say your build looks great and though it is not a foamie it is a good looking unit.

I am planning on covering the outside with 10/12oz. canvas. I am not too sure what I am going to do with the inside as of yet. I was going to just use old bed sheets. I am now interested in what the canvas will look like once it is done. I may go with a 6/8oz. canvas for the inside. Like the rest of the build all is subject to change at a moments notice.

[ghcoe]

Radius was dry so I popped it off the forms and cleaned it up a bit. Feels pretty solid.

Roof radius finished

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So this is my first use of the Gripper.... I was a bit skeptical about primer as a glue, but once I opened the can and started to stir it I was impressed. It stirred like a nice thick glue

So the test was on. I am attaching the sub roof with a combination of Great Stuff and Gripper. I first applied Gripper to the bottom side of the trailer roof. I then applied Great Stuff to the outer edges of the sub roof where it will come in contact with the bulkhead and the galley sides. Then I applied Gripper to the top of the sub roof where it will come in contact with the bottom of the roof where I had already applied Gripper. I carefully slid the sub roof in under the roof and then simply pressed the sub roof against the roof and it became as one. I let it set there for a bit just to see if it would separate. After about 5 minutes it was still attached . I had to finish doing some Great Stuff touch up and had no fear that the sub roof was going to fall down as I did that.

Gripper Gripping.....

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[GPW]

NICE hatch !!!

[atahoekid]

You did a great job with that radius. Not sure why anyone would have an issue with packing tape. It does a great job of controlling foam out and it protects the surface of whatever it's stuck to. Keep up the great work

[S. Heisley]

George, I'm enjoying your build and your innovative ideas.
I look forward to seeing more!

[djdawg]

I am a newbie....don't even have a trailer yet and have been debating between using foam or wood. Thank you so much for your pics and step by step process! What you're doing are things that I think I can actually do! It's easy to understand your process with the pics and I like the design of your unit...it's what I was I hoping to do myself. I liked the idea of a foamie but never saw too many with a galley so hence my trouble with deciding. Now I can watch yours come together!

Would you be up for (heck I'd even buy them!) sharing your original plans with dimensions, etc? I know some things have probably changed for you as you've been building it but it would be a nice starting point...

Thanks again!

[djdawg]

I went back to see if you mentioned it but what type of trailer are you planning on putting this on? Is it used or new and if new where can I get it?

[ghcoe]

I am a newbie....don't even have a trailer yet and have been debating between using foam or wood. Thank you so much for your pics and step by step process! What you're doing are things that I think I can actually do! It's easy to understand your process with the pics and I like the design of your unit...it's what I was I hoping to do myself. I liked the idea of a foamie but never saw too many with a galley so hence my trouble with deciding. Now I can watch yours come together!

Would you be up for (heck I'd even buy them!) sharing your original plans with dimensions, etc? I know some things have probably changed for you as you've been building it but it would be a nice starting point...

Thanks again!

Thanks for the complements.

I have plans on paper, but the plan has changed some during the building process. It is a pretty general build all in all though. Take a look at the first page of the thread there is a picture of the original design. The profile and shelf heights have changed a bit and I am planning on moving the window into the body from the doors. but the basic idea is there. If you need more let me know I will see what I can do.

I went back to see if you mentioned it but what type of trailer are you planning on putting this on? Is it used or new and if new where can I get it?

I am planning on using a Harbor Freight 4x8 trailer.

[djdawg]

Thanks George....That's the exact size and type of trailer that I used for my hot dog cart so I've been down that road....sweet!

Look forward to the rest of your build!

[ghcoe]

Note: This process was not used in the finished build.

Been pretty busy here for the past few weeks. Trailer time was here and there between other projects and trips. Been doing a couple of experiments as well. Reaching near record highs here so I thought now it is time to keep cool and catch up.

So I wanted to make the doors edges and edges of the trailer solid in case something should hit it. I played with a couple of ideas. Both ideas will work for different applications it turns out.

The first idea was to use flashing. I can get 1"x2" flashing here at a good cost. Does not weigh much, is galvanized (no rust or rot) and is pretty thrifty. Being a true 1"x2" it works great with the 2" thick foam. So my idea with this is to glue it to the outer edges of the door frame before I lay on the canvas to create a solid door frame.

1"x2" flashing

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First I cut to size with metal shears.

The cut

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Now to drill some holes, I will be using carriage bolts to go through the foam and hold the inner door frame on.

Drilling holes

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[ghcoe]

Note: This process was not used in the finished build.


Since I will be using carriage bolts there is a square lock that they use to keep from spinning while tightening them down. Usually you can just force them, but since I am working with foam and flashing is fairly thin I thought it would be better to pre-make a square hole in the flashing. So I made a simple jig to get the job done.

Block of wood drilled the size of the carriage bolt diameter.

Making the jig

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Then place the carriage bolt in the hole and give it a smack with a hammer. I marked the bolt head with a line so I know which way the bolt needs to go when the flashing is in place.

The jig

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Place the bolt through the flashing and then into the jig, make sure the line is in the right spot, and give it a rap with the hammer. Now you have a square hole without distorting the flashing.....

Making square holes

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[ghcoe]

Note: This process was not used in the finished build.

Square holes

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[Wolffarmer]

Cleaver guy

Randy

[ghcoe]

Note: This process was not used in the finished build.



Here is a couple of shots of how it will look.

Inside

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Outside

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