Okay, I made some visible progress. got the roof building complete and trimmed the excess ply off the sides. also cut out the roof vent. next step is gluing a layer of 1/8 ply along the galley wall edge so that I can trim that wall excess off too (the green visible at the galley).
14.5x14.5 cut out compete! the glue bonded well and my minimalist works seems to be working. only one spar on the front edge, the other sides seem more than strong enough for the fantastic.
a shot of my "junction box" fantastic wiring is waiting in this cavity for me. also I spliced my ceiling lights together here, I have access to this area if I pull the vent in case I have a problem down the road.
the main roof spar. this is the only 1x1.5 I used on the roof.
I couldn't help but test fit the Fantastic
me standing on the vent cut out. no framing in this piece and it easily supports my 185 lbs over a 12 inch gap. I did notice significantly more flex if turned 90 degrees so that the "bendy" bias of the ply was spanning the gap. however if turned the correct way I felt no deflection and can see just a little bit in the photo.
profile shots without the "wings". I routed off the excess of the side walls that I nested the roof into. in hindsight, I would have routed off that excess after installing the roof foam and before installing the roof ply. I had some fit issues with the roof ply binding against the side wall ply. that could have been alleviated by cutting flat to the foam, then bonding the roof ply across both the foam and the top edge of the outside walls.
the rear galley area. I am 13 inches from hinge spar to bulkhead. and the hinge is at eye level. should be perfect to add 1 ft of cabinets above the counter
It looks messy, but this will get cleaned up after I glue down some plywood skin onto the foam face of the galley walls. I didn't want to burn through the foam with the bearing bit, so I just stoped routing at the hinge spar.
some imperfections in the roof. my idea to add extra bonding/strength by screwing through the ply and foam into the wood framing caused some indents which transferred throught the router to the wall cut. This should all get hidden by the aluminum and trim, but I will still do a rough fill with epoxy and wood flour. the lifting of the ply was only evident after I routed off the side wall excess. this is where the roof and walls were binding and it caused a whole area of the roof to not bond to the foam. I will fix this by drilling small holes lengthwise on and injecting epoxy or construction adhesive (probably epoxy), then clamping down to get a decent bond between the ply and foam.
after working out the above, I will fill and epoxy the edges of the cabin.