5' X 10' Grumman 2 Sort Of

[KCStudly]

Many use a cheap sheet of 1/4 underlay or luan to make a master template of their whole profile. All details are draw and/or cut on the template first, both to check for oopsies and to have a permanent record of locations. They make a good router template, too.

[RunnerDuck]

This is actually three days rolled into one.

I've been working really hard and making good progress. I've got the inner plywood walls trimmed to my pattern and the outer plywood walls trimmed to the pattern.

I've got the outside aluminum siding on order and I will pick it up Monday.

Here are a few photos of the last few days.

This is trimming the plywood with a router trim bit.

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Trimming out the door opening.

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And finally a fit test of the walls! This is a big milestone and I'm really excited with how well they fit

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Things are really starting to come together. It's really something to see it actually starting to look like my drawings. I still have a long way to go but at last some really visible progress!

[KCStudly]

[RunnerDuck]

It's been a couple more days and I've been working on the roof trusses. I've got the roof trusses all glued up. They are 1 1/2" X 1 1/2" made up of 3/4" thick mahogany.

I'm just glad that I've got lots of clamps!

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I cut down the piece I trimmed from the top of the core to make truss spacers.

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Here's a shot of the truss spacers and trusses being test fit. I think they are going to work great! They will go on top of the 1/8" plywood ceiling.

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It's great to be showing lots of progress. I just may have myself a teardrop someday

[guymi]

Superbe

[ELM]

Looking nice.

[Vedette]

Hope it is ready for the Farm Gathering .....We have a "Show 'n' Brag" for you to show off your achievements!
July 14 - 17th.
Your progress looks great, don't let up.
Good Roads
Brian & Sandi

[RunnerDuck]

Only time and a lot of work will tell.

Don't count me out just yet

[RunnerDuck]

Day 23 consists of two days. The first day I dove off island to pick up the Dibond that I'll use for the outside wall covering. Then I picked up four sheets of 1/2" Baltic Birch plywood for the inner wall and some of the cabinet structure.

The next day I rough cut one of the sheets of Dibond with my scroll saw. It took a few tries with different blades to find one that cut fairly smooth. I traced around the pattern with a Sharpie and then moved it aside to make my cuts.

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Once I had the rough cut done I put the pattern back in place and routed around it with a flush cut router bit. What a mess it made. The cut was perfect buy my shop was a mess. The black plastic inner core of the Dibond just came off in tiny pieces you can see on the plywood and floor.

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As soon as I get the second side cut out I should be ready to start laminating up the walls. It sure is getting exciting now

Stay tuned!

[RunnerDuck]

I finally started putting the walls together. I started with the inside skin first. I spread PL glue all over the core with a notched trowel and then put it on the birch plywood.

Since I drink a lot of milk and saved up a bunch of milk cartons that I use as weight clamps. I do believe they will do the trick.

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The adhesive has a 24 hour clamp time so won't know until I check it out this morning.

I think I'll add the rigid insulating foam next.

Stay tuned!

[ELM]

Good idea there. I use steel for weight since I have a lot around. I can hear my Dad saying. That's the way to use your head for something other than a hat rack. Your moving right along there and it's looking good.

[RunnerDuck]

Thanks for the compliment ELM. I just don't have much heavy stuff around so seemed like the best I could come up with.

I couldn't use empty wine boxes but it's really difficult to refill the empty bags inside.

Today I glued in the rigid foam insulation and I think it turned out great.

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I cut groves in the foam to run my electrical wires to my light switches and tail lights. I laid in some heavy string and tied a labeled washer to each end. That will identify each string and prevent it from pulling back through any holes. Hopes are high that it will work as planned.

Next up, glue the outer plywood on and then glue the outside "Dibond" skin on.

I'm getting pretty excited to get the first wall done.

[KCStudly]

If your wire pulls are dead straight the string trick should work okay. However, if you have any turns or corners and are pulling anything more than just a couple of wires with minimum resistance, the string can cut into the foam and cause a bind. First hand experience here. It will go eventually, but you may sacrifice some insulating value and your wires may take some shortcuts.

[RunnerDuck]

Thanks KC for the comments. One thing I always respect is "experience", especially "bad experiences"!

I've made every effort to keep the groves fairly straight. There is one with a little curve I'm a tad worried about but I think if I'm easy with it, it should work.

My other option is to run the wire with the little curve now and just have a coil of wire to deal with at one end, then there would be no binding. I'm still thinking

Thanks again!

[ELM]

I've used poly flow tubing for wire conduit when I need to run wires through and in my steel tubing. My be it would work in your foam also.