slow build journal

[rick e]

Well actually I don't have any sawdust yet. I've been scraping and wirebrushing and applying rust converter. I bought a Harbor Freight flux wire welder for $89 with my coupon. Now I can reattach the fender that came off and maybe strengthen the frame some.
My local lumber yard says they have some 1/2" exterior fir ply, not common around here, for cheap because the school board stopped ordering it. That's where I'm going tomorrow.
My problem is the garage, it is full of stuff. Including a motorcycle that didn't sell on ebay. That sale would have financed a bigger better Benroy. Oh well. I may get another canopy and start the woodwork in the back yard, (this is Florida) That way the sawdust can blow over to the neighbors yard.
The plan is for a 4x8 modified Benroy with 1 self built door, a horizontal slider window on the other side, a half hatch meaning not all the way to the rear bottom, an A/C slide out on the rear side (under the galley) and fiberglass finish.

Comments, ideas and suggestions welcome.

[rick e]

[rick e]

I was able to do some cutting today. It gets dark so early.

[rick e]

I left some room for a wider window. This cutout is from one I got on ebay and it is crap. I'm still looking.
Decided to remove the bottom radius from the door to ease trimming it.
I will clean up the outer cuts with the router and templates. Finally found it after searching all morning in the garage. Haven't found the bits yet.

[rick e]

Ready to start assembling the thing now. a lot of cutting. I had some spray rubberized leak seal I decided to use on the underside, bad idea. Had to go buy 2 more cans at $9 each. Could have bought a gallon for $8.00.

[Junkboy999]

Great start. Yep the router really mas the cutting easy.
Keep us posted.

[rick e]

Now I feel like I'm getting somewhere. Too crowded in my little garage, going to have to move out back under a canopy. Almost broke down and bought a Kreg pocket hole jig today, I usually freehand those holes. Not on this project though the galley and cabin needs to be cabinet work. Precise!
I am thinking of cheaping out on the converter. I wanted a "mighty-mini" they are pricey and I don't need 45amps. Reading back through the posts here I saw many folks like the Wifco. I am looking at the very cheap "Heng" on ebay.

[rick e]

I had a battle bending the 5mm Revolution ply for my ceiling. Didn't think it would be that difficult. Lesson learned: stick to the 1/8 birch if you can get it.
But it is in there and I am satisfied with it. I don't think it will be as difficult when I bend the same stuff for the skin.
Time to get serious about wiring. I haven't ordered my converter yet.

[rick e]

I am still thinking about how I want the inside cabinet and the galley. Local store only has 1/2 and 3/4 insulation. I haven't decided what to put in the roof yet. Someone here said they doubled it up.

[AlgoDan]

Looking good Rick, well done...

[rick e]

Slow 2 weeks. I was applying CPES but we had a cold spell (30's) so I stopped. I ordered some epoxy resin and will buy some fiberglass cloth locally just to test the process but haven't ordered the main supplies from Raka yet for the skin.
My WFCO 8725 converter came today. I am not overly happy with it as I thought it had at least one more breaker holder. I guess I will put a 20amp for the A/C and a 20 for the 2 recepticles. I ordered it from American RV as the price was right and thought I may have a better chance if I need the 2 year warrantee. The WFCO website says if you bought it from ebay don't bother them or something to that affect.
So this weekend should be in the 80's and I have my list of to-do's....CPES, wiring, interior cabinets and utility run. Also insulation, cutting those little shapes is a tedious job.
Probably will buy another canopy and move the whole process out back as I have threatened to do. The motorcycle is starting to show corrosion from being outdoors and needs to go back in the garage.

[rick e]

the famous gravity clamp.

DSCN2563-2.jpg (159.01 KiB) Viewed 2816 times

This is an appropriately named build. Slow progress is better then no progress though.
Fiberglassing the outer panels is taking some time and the weather has not cooperated.
I did move my shop outdoors and that is working out ok.

[rick e]

ready for skin

[rick e]

epoxy resin is great stuff to work with. I am using 1.5oz cloth. I have seen mention on here of much heavier, up to 6oz, is that needed? I look at it as "weather resistance" for the plywood. This is my first time fiberglassing this large of a project so I may be wrong. Anyway I like working with it and am happy I choose it for the skin.

[Corwin C]

epoxy resin is great stuff to work with. I am using 1.5oz cloth. I have seen mention on here of much heavier, up to 6oz, is that needed? I look at it as "weather resistance" for the plywood. This is my first time fiberglassing this large of a project so I may be wrong. Anyway I like working with it and am happy I choose it for the skin.

1.5 oz cloth should be adequate, and it will be a joy to fill the weave of such a fine cloth as compared to the 6 oz. If you are at all concerned about wear areas or such, it can be doubled up. In essence the cloth is there to prevent the epoxy from allowing any cracks/joints to echo through to the surface.