another foamie build thread

[GPW]

The smaller panels might be easier to handle , although both would work eh ?

[KCStudly]

I haven't got to that point in my build yet, but will be using two layers of 3/4 thk x 2 ft wide foam running across wise. I'll need to experiment a bit with dry fitting to see which way I want to do it (place each piece separately vs. smaller panel glue ups), but I doubt that I will do it as one big glued sheet.

My reason for thinking that across wise is better is because each seam will be shorter and therefore easier to sand/fair the joints. Also, if the joints aren't perfectly fair after sanding and they telegraph thru the canvas outer skin, I think it would be less ugly for them to go across wise, giving a spar like appearance, rather than stripes like a skunk (stinky looking to my eye). Randomly placed lines across wise would look better than randomly (non-symmetrical) lines running lengthwise.

The tight radius at the front might be done with longer glued up panels, kerfed back to back if need be.

[scuba1978]

Great points guys. I do intend to kerf the radii either way. Perhaps a skunk would be a cool color scheme!

[GPW]

Using two layers you could stagger the joints ... Unless you lived in Colorado , where the joints could stagger you ....

[scuba1978]

Yesterday I welded the rear trailer jack on the frame. And I glued on the walls.


There were a few gaps, so I covered them with painter's tape, and I poked the nozzle of some great stuff into the gap and filled them up. It worked great except for one blowout.


I let it cure overnight, then I got after it!

[scuba1978]

Today, I cut the front-top-rear panels into 73" x 24" panels, then glued them into 3 larger panels. I then cut a 1" shoulder all along the inside edge of the walls. I made a sweet gage to mark it, then cut it with a razor.



Those are the glued panels behind the wall. I cleaned up all of yesterday's glue expansion. Finally, I made a hot wire kerf gun.

I also glued in a ceiling brace over the doors. Tomorrow should be a roof, and maybe some bracing for the fan..

[GPW]

Great progress Scuba !!!

[scuba1978]

Thanks GPW! I went and bought door hinges and rubber gloves today, then I started kerfing the first radius.

[scuba1978]

Layed some gg in the slots, and bent 'er up!
. That's probably all for today!

[kudzu]

You're making good progress. The bunk is getting a nice test.

[GPW]

That bent Nicely didn’t it !!!

[tac422]

That looks Great

[scuba1978]

That bent Nicely didn’t it !!!

It did, but I may try a new kerf tecnique. The gun I used was tricky, and it left uneven kerfs which bent unevenly, and some places cracked because of it. It was still reletively easy, but it required/s e great deal more glue and hand-finishing to get a nice surface. I'm not trying to build the Taj Mahal, but I want a certain moderate level of aesthetic finish work. I did not attach the curved piece yet, I used painter's tape to cover the walls, then used them as a form to glue the radius. I felt like it would have been a bit difficult to glue everything at once. Now, I can put the pre-formed radius on after some love with a flapper wheel.

No real progreess today...went fishing. Caught nothing but a mild buzz from a cigar and a few sips of some nice scotch a friend gave me!

[GPW]

Scuba, I’m now thinking for kerfed /rounded surfaces , problem could be prevented by first gluing on a LIGHT material (old sheet) on the outside surface to be bent ... relieving the tension stresses , and making the bending safe ... no cracking , leaving a smooth outer surface ...

[lthomas987]

Scuba,

Are you just using a solder gun with a block of wood to fix your depth as a foam cutter for doing your kerfs? Or is there something else going on there that I am not seeing?

Laura