The Poet Creek Express - Foamie Hybrid

[OP827]

First let me say that I really am not a bodywork kind of guy. I give up seeking perfection far too soon....

- Me too. We just talking here about the options, so that each of us can make an informed decision, and you are welcome!

[KCStudly]

Had a good night in the shop. Hit another mini milestone getting all of the roof foam dry fit.

Ripped the panels that needed to be ripped. I ended up with 4 of the 2 ft wide x 64-3/8 long panels left over, plus some bits and pieces, so I suppose I didn’t need to piece so many sections together for the first layer. Not sure how I over estimated except to say that you can piece foam together with relative ease.

Several of the holes for the wires running thru the roof spars were at or slightly above the middle of the spars. So even though the routed grooves in the first layer of foam were deep enough for the wires, where the wires went through the spars they still tended to hold the 2nd layer of foam up a bit. So I ended up routing corresponding grooves, though shallower, in the underside of the top layer pieces. For the last panel where the ceiling outlet box sticks up thru the first layer of foam a little, I routed that area out about 3/16 inch.



The rest was just a little bit of sanding on the edges to get the panels to fit just so.

In prep for adhesive, I ran another strip of 2 inch tape to mask the front side of the hinge (I had done the rear half sometime back).


In typical fashion, when I’m happy with the progress I take more pictures!

[OP827]

it's coming together KC, looks good!

[tony.latham]

Have you and Karl tried to lift it up to guess the weight?

T

[KCStudly]

Sort of. Either of us can lift the front without too much trouble, but it is a bit of work. I'm pretty sure that it takes both of us to lift the back now. Unfortunately this is deceiving because the build cradle is attached to the bottom so we are also lifting a portion of that. But that too is even more deceiving because the cradle does not go all the way to either end, so when we are lifting it is teetering around a point that is about 1/4 of the length of the cabin (lifting 3/4 with 1/4 counterbalancing and helping to lift).

Karl thinks it's about 500 lbs maybe less, my guess is a little more. That's with the doors laying down inside, but w/o the windows, door hardware, hatch actuators, galley counter, and, of course, does not include the TB, electronics or battery. With all that other stuff and the canvas, I'm gonna guess at least 650 lbs (wild ass stab). IIRC the trailer weighed 472 lbs with the roll around tires (27 inch street tires on steel rims). At the moment I'm not sure if that included the coupler universal spud. Compared to the temporary tires and wheels, the larger AT tires probably weigh a bit more despite being mounted on aluminum wheels.

Still, I think I'm on my target for about 1200 lbs empty; maybe doing better than that by a little?

Now I'm going to have to figure out a way to weigh the thing... see if the galley end maxes out my bathroom scale.

[OP827]

KC, you could do a 3-point trick to get to exact total weight with bath room scale w/o exceeding scale limit. You could weigh at two established points in the back and at one point in the front, since the front seems to be lighter than 250lbs.

[GPW]

1200# not so bad eh, considering !!!

[KCStudly]

Yeah. It would be a pleasant turn of events if it is lower, but I'm not going to lose any sleep over it and am not worried about it. (Wouldn't want to jinx anything.)

All this talk about the weight and I might just have to get distracted by making up some spacers and a trammel to get a set of corner weight readings.

Then again, if I did know what it weighs now I don't think there is anything I can do about what I have done so far, and I don't think I would change any of my plans going forward. So it isn't a priority at the moment.

Maybe I will be able to borrow the dynamometer from Mr. B to get a scale weight when we hoist it up to lower it to ground level. IIRC that is rated to 3k lbs.

[KCStudly]

Add to the list of things to do before canvas, install blocking and extend wire ways for the side clearance lights.

[Sheddie]

Thanks for the glowing endorsement, OP.

I bought 16 yds of #12 (11-1/2 oz) cotton duck cloth a very long time ago, and will probably use it; although I do waffle sometimes and think that I might switch to glass. Still haven't decided on glue vs. epoxy.

I just have to chip in here. I am no expert here when it comes to building with foam and covering with painted canvas. But for me I think back to when my dad and I built our boat, around 30 years ago. Ply wood construction with fibreglass and epoxy resin, sprayed with a high build primer and finished with two pot reaction lacquer. The paint has never been touched since new and is still looking good. Ok, the canvas idea has been around for a long time, it was being used on boats and things, long before glass. It may be tried and true, but so was the Model T.

[GPW]

So was lightning a fire starter... apples and oranges... pick your poison...

[aggie79]

KC,

I love the "pre-skinning" look of the PCE. It's a great mix of form, function, and style. I look forward to seeing how you finish the exterior.

Take care,
Tom

[KCStudly]

I can certainly see both sides of the coin (pun intended)... or fence (I'm sensing a little edge here, so please play nice ...GPW ).

The pros and cons have been discussed at length. There are advantages and disadvantages to both systems, and I still haven't decided, except that I think I will at least be a little thrifty and use the canvas instead of glass: 1) I already paid for it and would probably not break even reselling it, 2) Karl is convinced that the canvas will lay down over the corners easier than glass due to its flexibility (especially at the door jambs where I want minimal radius), and 3) I don't like the itchy from working with glass and I melt like a Popsicle, so covering up to work with it is not a good option for me.

[OP827]

I think both canvas+TB2 and FG+epoxy have their well deserved place in the builds and as this board being a place for a free speech each of us is doing what suits our design intent to the best.
KC, I would be interested to see if you decide on canvas+epoxy method. As many times mentioned by Glen, trying a sample would help in the decision making process.
I also think that fairing canvas that were impregnated with epoxy will be easier, why don't you try both samples (TB2+canvas vs epoxy+canvas) to compare the look and fairing workability?

[KCStudly]

I probably will do just that... when the time comes.