The Charlie Project

[rebapuck]

I had a sailmaker do my awning. I got what I asked for. A 7x9 rectangle of Sunbrella. I neglected to account for the curves as the rail went slightly around each end of the trailer. Always had a sag over the door. Measure only the straightaway.

[Forrest747]

Well the awning rail is installed. Tomorrow is fabrication of the awning.

[Forrest747]

well the yard sale is going well. got rid of a couple of sleeping bags so it helped buy the vinyl railing insert. went with black, it works for me. looking at the sport nylon I am thinking of going with something heavier like duck cloth or sunbrella. the practice of fabric fabrication is going well. EMT conduit for the frame. Just need to figure attacment points on teh trailer.

[Forrest747]

Worked on the awning supports today. i went with small footmen to hold the awning to the trailer. While at lowes i decided to go with white pvc. they had right angle and tees that were threaded. this i believe will make it easier to take down and store and i do not have to worry about gluing it just right. It also allows me to be more modular with the parts and the different types of awning or changing room. Ordered some keder rope and basting tape from sailrite and will be here later this week. been watching many sailrite videos on youtube on how to construct an awning. Thank you Sailrite.

[S. Heisley]

Did Sailrite use PVC or is that your creation idea?

[Forrest747]

They used aluminum and other metal for the awnings. The pvc screw pieces made sense. Easy to break down and adjust

[Forrest747]

CHARLEY
Plywood 1/4 50
Plywood 1/2 100
Plywood 3/4 200
glue Gorilla 30
spars 2x4 50
lights 112
battery 89
Battery box 1 10
mattress 100
doors 40
roof vent 40
epoxy 150
screws 20
paint 60
fiberglass 10
converter 176
wire 0
fuse block 30
rails 40
wood 40
outlets 15
switches 12
12volt outlet 15
hardware 50
poplar 30
door latch 35
hinges 100
awning rail 50
vinyl 20
sink 90
tile 0
Epoxy Grout 50
cherry 264
water tank 100
grey tank 100
pvc 20
water pump 100
hose 20
fittings 20
steel 250
coupler 40
axel 275
rims 50
tires 200
running lights 100
windows 300
cooler 30
Fenders 70
Total $3753


If i make some changes that i learned from this build I calculate from the spreadsheet to build it for $2200. if i do things like cherry paneling then the cost goes up.

[Modstock]

Let me know if ya need something sewn up . Oh, how did the trip go ?

[Forrest747]

Some progress on the awning. I got the sewing machine to work. Bobbins i hate you. Ok that is out of the way. After getting the nylon hemmed and breaking two needles and getting the denim needle (who knew right) I sewed the keder rope to the nylon. its an ugly job and messed up in that about four inches of nylon bunched up and was sewed onto the keder rope. will need to be patched. I am sure this sewing thing will get better. a little worried about how stable it is really wobbly.

On the positive note I have found a Trader Joes so i am content with life.

Midnight update.

Burning the midnight oil and now have the pockets for the pvc pipes and assembled for the first time. i like it. ok learned alot on doing this one and what not to do or make some workflow changes. going to try and do the next one tomorrow.

[S. Heisley]

It looks like you did a good job, Forest. Anything more will fall under the "improvements" title, ey?

What size PVC did you use? is that 1"?

[Forrest747]

I used 1/2 inch schedule 40 pvc. I am not sure how it will do and if it breaks i can always go bigger.
I can foresee an issue with how the rain drains off the awning but just going to see if it actually happens. Labor day here we come
You take the trailer out and something happens and you think i can change that or that is nice feature.

[Forrest747]

Here is the issue I was having with the contact cement. wasnt holding the vinyl in place.
Using a half round trim piece I used brads to hold into place.
the panel i made is too big and heavy for the four magnets so going to scrap it and start over. may use velcro
pvc cross arms for the awning
pvc legs for the awning as well I like how easy they are to screw in and makes it easy to adjust the angle.

[Forrest747]

I messed up big with my windows. i ordered them from two different sources and did not get the right thickness and the trim rings were not going to work.


So I thought ok Vinyl basic black with snaps would look great, great idea no way to figure it out. it came down to i had no idea how i was going to attach it to the wind itself to look seamless or at least nice.


So spent the weekend making a couple of wooden window frames and used the trim ring as a guide and did my best to free hand it with the router. I still have an issue with one of the sides not sitting flush with the cherry paneling, in fact there is about 1/4 to 3/8 inch gap. will figure a way to fill it in. Next is the curtains I am pretty happy with it.

Update:


Worked on the curtains and pretty happy with them. Just four simple panels, right now I am using bungee cords as the curtain rods.

[Forrest747]

I have blown up my lower galley inside. I do not use the water tank like i thought i would, and i need more storage space so i took it out. Along with the pump and some interior plywood. Going to have to redo the internal support for the drawer and protect some electrical (one wire did get sawzalled). Moved the battery to behind the cooler to the right, i still need to figure out how i am going to secure it. This was after a successful trip in southern Utah. I am also going to be removing the grey water tanks and rig up some sort of smaller drain line. Tons of fun and also new trailer logo

[rebapuck]

Live and learn. Every time you go out, you'll be thinking of new and improved. I guess that's why so many immediately start thinking #2.