Off Road Grumman 2ish (5x5x10) Build

[DWT77]

Got the galley hatch cut out of all three walls today. Made a couple of mistakes that I can sand out when I glue them all together.

[DWT77]

I think I will wait and glue them together until it is time to start on the galley

[KCStudly]

It looks like you plan to laminate a thinner finish wood on to your ply ribs. I would probably glue those together now while everything still matches. Ply is pretty stable, but you might still get some changes over time (best to lay them flat while in storage).

I built up my own laminated curved pieces for the edges of my galley walls and didn't install them right away. When I went to install them they had changed from their original shape significantly. I realize this is somewhat of an 'apples-to-oranges' comparison, but still, better safe than sorry.

[DWT77]

It looks like you plan to laminate a thinner finish wood on to your ply ribs. I would probably glue those together now while everything still matches. Ply is pretty stable, but you might still get some changes over time (best to lay them flat while in storage).

I built up my own laminated curved pieces for the edges of my galley walls and didn't install them right away. When I went to install them they had changed from their original shape significantly. I realize this is somewhat of an 'apples-to-oranges' comparison, but still, better safe than sorry.

I think I will take your advice and get those done. Thanks!

[KCStudly]

[DWT77]

I got a little more work done this weekend. I made a mistake a while back with my MDO board for the exterior wall. I remember telling myself when I go to cut the exterior wall be sure to flip the board so the MDO paper side will be on the outside. Well I guess I got in a hurry and didn't do it. So now I have one exterior wall that will have MDO paper on the side and another that will have plywood. I was going to fiberglass the roof anyways since I will be using 1\4 bendy plywood for the roof. So I decided instead of going all the way back down to Dallas to buy another sheet of 5x10 MDO (Can't get it in OKC) I will just fiberglass the sides as well. Hopefully it all turns out ok but not an expense I wanted to have to deal with

[DWT77]

The weather has been a little cold and raining. I decided to start on my bulkhead since I couldn't pull the trailer out and start on the floor. I got the bulkhead framed, insulation cut and started gluing the birch for the exterior.

[KCStudly]

Looking good!

[DWT77]

Looking good!

Thanks KC. Trying to get there!

[DWT77]

Tonight I had to sand down the insulation on my bulkhead. It was sticking up a higher than my frame boards in some spots. Which is really dirty work btw. I also was able to router the birch plywood I had completed on one side. Then got it sanded and stained.

[Dirtclod]

I am really enjoying this build so far. I am just about to start making sawdust on my build. I like the torsion box bulkhead. I have been going back and forth on what to make mine out of and after seeing this I am going to do the same.

Keep the pics coming.

[DWT77]

I am really enjoying this build so far. I am just about to start making sawdust on my build. I like the torsion box bulkhead. I have been going back and forth on what to make mine out of and after seeing this I am going to do the same.

Keep the pics coming.

Thanks Dirtclod

I read your build journal this morning and I was going to post on it to mention I am in the process of building my bulkhead. I located my cross member boards to match where my cabinets will be mounted on the bulkhead. That should give me plenty of support for the pocket hole screws.

Also if you are wondering why I have a 20" x 12" notch in my bulkhead. Since I will be towing mine with a jeep I don't have any room for longer items, canopy tents ect.... This way I can open up the galley and slide them in under my mattress storage area that will run the length of the trailer.

[DWT77]

Last few days I filled the knot holes in my plywood with epoxy/filler. Then sanded the board down with 80 grit paper. Then I got two coats of the mix on it. I will do the other 2 coats tomorrow. Then it will be ready to flip over and fiberglass the bottom side. I also tape off the edges where the walls are going to sit. My plan is to epoxy/filler/paste/seal them when I go to install the walls. Doing a dry test fit first because epoxy doesn't seem to wait on anybody

[DWT77]

Well my first attempt at fiberglass wasn't the greatest. Good thing I am not building a kayak! For my application (pics below will be the underside of the floor) it will work though.

I will do a little sanding and then spray it with bed liner. Should cover my ugliness up and be weather sealed.

Hopefully my sides will be a little better. I will fiberglass them while on the workbench as well.

[swoody126]

DWT77, using a SQUEEGIE may help

i have had similar results and have been using the stuff FOR YEARS...

when i got turned onto SQUEEGIES the job went faster and the results have been much more pleasing to the eye

once you cut the glass and lay it down on your surface that has been pre wet put a cup of POX in your off hand and begin pouring a small amount in the center and SQUEEGIE the POX out toward the edges

you can second coat POX as it gets tacky and will have a thicker coating rather than sanding when dry and adding the 2nd coat which can result w/ 2 layers

your intention to pre-coat intended flat surfaces on level flat surfaces is SOUND

sw