BEULA - a foam Winter Warrior with aero front

[GPW]

Living hinge ...? You guys know how to make a canvas hinge ... ??? it’s simple ...

[cpowell243]

I wondered about using canvas but hadn't seen anyone use it for a hinge. My travel is only 15-20 degrees so it seems any flexible material would work. Unfortunately, already ordered a MacMaster-Carr harsh weather hinge - to the tune of $80 - so guess I'll go with that. Still working the on rear wall and making progress as time allows.

[GPW]

Here’s my idea , based on years and years of making plastic film hinges for my Foam airplanes ...

[cpowell243]

Thanks Glen - living hinge just arrived and seems like the safest option.
Here's where we stand:
Built hatch by cutting panels, gluing bedsheet to the underside of each panel, then attaching panels to the rabbited spars, which were already attached to the walls with metals L-brackets and GS.
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Hatch removed to attach 3/4" aluminum U-channel to stabilize the polystyrene and create positive surface to mount molding.

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Then added plastic molding to the main body, again to stablize the 1" poly - did I mention all the comments I have received about the Wyoming wind?

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Using this stuff bought at HD:

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Then attached molding to the bottom of the hatch using:

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To create:

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Now I work on the hinge. Plan is to use 3" living hinge with a bicycle inner tube underneath to seal and aluminum strips on top to prevent dimpling of the plastic (based on my reading of living hinge info):

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Feedback welcome, as always.
Charlie

[GPW]

Moving right along !!! That hinge looks interesting !!!

[OP827]

Hi Charlie,
I have some feedback on the hinge.
I have no experience with such vinyl hinge, but do you think it is strong enough for the hatch weight to not cause it wear/distort prematurely?

Since you are using the rubber strip for weather seal, then a usual stainless steel hinge would also work?

[cpowell243]

THanks for question and following my thread. The rubber would've worked with a steel hinge, but I thought the living hinge would make things certain. The weight rating of this hinge says it should manage over 10x the weight of my hatch (or more) which, while I haven't weighed it, I'm guessing weighs in at around 60 lbs I ordered the MacMaster-Carr hinge rated for extreme weather conditions. It's pretty stout. Install is Saturday after I finally bolt the body to the trailer base.

[OP827]

Wow, I did not know that this vinyl hinge would be that strong, so it is rated then at approx. 600lbs (if 10 times of 60lbs) load for its whole span/length?

[cpowell243]

Madjack researched the load-baering capacity of the McMaster-Carr hinge and says (in 2012):
"at a weight rating of 100#s per inch for the 2", I can't imagine needing anything wider."
That would give me a maximum load of 7,200 lbs. Don't know about that, but seems like 60 lbs should be ok. More worried about the 2X2 splitting first.
Ch

[RAYVILLIAN]

Morning Charlie

I don't know much about the heavier living hinges. I used a cheap lighter one on the old trap door on WW2 and it started to show signs of wear after 3 yrs. but it was a cheap ebay version. My hatch has a 6' piano hinge that I salvaged from a house trailer I was helping to tear down about 8 yrs ago. I covered it on the outside with some collapsible vinyl irrigation hose I got from a local farm supply store. My hatch is alot heavier than yours though. My main concern with a vinyl hinge would be winter camping. Plastic gets brittle when it gets cold and tends to break easier. If you don't winter camp, which I don't any more, that won't be a problem.

Keep up the good work. What you done so far looks great.

Gary

[starleen2]

Hi Charlie,
I have some feedback on the hinge.
I have no experience with such vinyl hinge, but do you think it is strong enough for the hatch weight to not cause it wear/distort prematurely?

Since you are using the rubber strip for weather seal, then a usual stainless steel hinge would also work?

That's what I did with the Ladybug. After a long search for a suitable seal – the answer was right under my garage door – the seal that is. I found that the seal that seals the bottom of a garage door is perfect for the top hinge and side seals. It has UV protection, remains pliable, and meant for constant use. I used it cover over the hinge and sealed the edges with aluminum strips







I guess any good hinge would work if you are planning on covering it with a rubber memebrane

[cpowell243]

I was planning to put my rubber underneath the hinge to seal the hinge/body contact point, but you both have me thinking maybe better to place on top. I too was concerned about cracking in the cold, since mine will be outside in below zero temps, but this one is rated for -40 degrees

from McMaster-Carr site:
Harsh Environment Plastic Piano Hinges without Holes
Made of polyolefin plastic to resist salt water, oil, solvents, extreme temperatures, and UV rays. Hinges have rigid leaves and a flexible center for smooth, silent operation. Mount on the surface of doors and frames with adhesive or fasteners. Hinges can be cut with a box cutter or razor. All are for indoor and outdoor use. The full range of motion is 280°. Temperature range is -40° to 180° F.
Ch[/b]

[cpowell243]

Finally some progress on Beula. Hatch is on. Design requires a total of 10 panels:
Rear wall is 3 folding panels on the lower left side, a lower right side panel, upper left and upper right panels, and upper and lower door panels.
I also have a door on each side, for a total of 10. Building the panels a slow process that involves a frame built with furring strips, filled with 2 layers of 3/4" polystyrene, then canvassed. Then filling, sanding, painting... you all know the drill.
I have all rear panels built except the upper door, which has a window.
Will be installing the upper right and upper left panels tomorrow, hinged so they fold up, then installing door hardware for the lower rear door panel, then build/install the upper door panel before moving on to the side doors. Should have some pics of hinge and rear wall tomorrow night.
Charlie

[cpowell243]

Finally some progress on Beula. Hatch is on. Design requires a total of 10 panels:
Rear wall is 3 folding panels on the lower left side, a lower right side panel, upper left and upper right panels, and upper and lower door panels.
I also have a door on each side, for a total of 10. Building the panels a slow process that involves a frame built with furring strips, filled with 2 layers of 3/4" polystyrene, then canvassed. Then filling, sanding, painting... you all know the drill.
I have all rear panels built except the upper door, which has a window.
Will be installing the upper right and upper left panels tomorrow, hinged so they fold up, then installing door hardware for the lower rear door panel, then build/install the upper door panel before moving on to the side doors. Should have some pics of hinge and rear wall tomorrow night.
Charlie

[GPW]

So good it’s worth saying twice ...