NT 5x8 Build Journal

[mcubberley]

This was my first build and also it was a done primarily as a way to help students apply the skills they were using in my shop class. We can all study books and the internet until we are blue in the face but real learning is solidified in the application of that information. I was looking for a unique way to get my students engaged, excited, and applying skills in a real world situation. The project was solely funded by donations and grants. Overall it was a great experience for both the students and myself and we will take what we learned from this project and start a new one next year.

Construction was done using hardwood ply for the sides, pine ply for the floor, ripped 2x4's for all the spar work, 5mm underlayment for most parts of the roof, and hardboard for the interior curves that I could hit with the underlayment. All wood ends and key parts were sealed with paint thinner: polyurethane (1:10) before continuing. We left the build with a flexible aluminum roofing product, flex sealant on the sides. All wood ends and key parts were sealed with the mix before continuing. We used a PD4045 for power distribution and a 30amp shore power inlet.































So that's where we ended up. Not too bad for our first time through. It was quite the challenge to balance aspects of the construction, teaching, and supervising student work. Not to mention making sure that everyone keeps busy and that what they are learning is documented and can be adequately seen by the administration. Not too shabby for a first-year teacher and it only gets better from here.

Thanks for tagging along and I will come back to this thread from time to time to add details and insights on the images. --Michael

[Gold5one]

Those teenagers did a nice job. I wish my shop teacher had given us a fun project like that. I only learned to build a bird house, and a bookcase for projects.

[mcubberley]

Those teenagers did a nice job. I wish my shop teacher had given us a fun project like that. I only learned to build a bird house, and a bookcase for projects.

When I started the job the storage was full of abandoned bird houses and clock. I figured it was time to change things up and not assign projects that the students just not going to connect with and later abandon. It's a waste of time, materials, and effort for everyone.

They exceeded my already high expectations. They responded well and got engaged. We all had a ton of fun and learned some stuff along the way. Mostly I wanted to make sure they had the confidence to try something of this scale. The first step is the hardest when you're trying something new.

Thanks for the feedback.

[mcubberley]

Well I just dropped 1k to get custom square doors, aluminum sheets for skinning, upgraded hubs and high speed loadstar tires. The aluminum goes on this weekend and then I need to get it all weighed. So excited to own a trailer I can be proud of.

[mcubberley]

I will say that getting to aluminum skin on has been a fun experiment. The roof is floated and tomorrow the side go on. I still need to trim out the fan opening and the door openings will come out as each side goes up. I choose not to contact cement them first because I didn't trust my skills in handling the sheets. I am very glad I didn't. Would have made somethings easier but I ended up needing to back out screws and repositioning a bit.

Too bad my new doors are still 12 days out. Guess the homemade ones will have to hold me until then. Very glad I got the skinning upgraded. Dollar for dollar its been the most rewarding improvement.

Lots of work and riveting seams is tedium. I should have rented the pneumatic and saved my tendons a workout. 5' wide would have made my life so much less painful. Still worth it either way. I'll add pictures tomorrow.

[mcubberley]

More trim left to add but mostly just waiting for my factory doors from Challenger Door to arrive.

[absolutsnwbrdr]

Pretty cool to see a shop class building something other than birdhouses. Can't tell you how many times I thought back to my shop class and would love to show my teacher what I'm building these days.

[mcubberley]

And this is where we are at until the doors come in. The wife can get to doing the inside. Lots of poly and some fun tinted stains. Should end up with a fun interior with lots of character.

[greygoos]

Looking good. Can I ask what type of trim you used?

[Woodbutcher]

Well done, it was nice to follow along with your project.

[mcubberley]

Looking good. Can I ask what type of trim you used?

It's 1" vinyl inset aluminum molding, mostly. The side leg is 5/8" and the insert side is like 1.25". Frankly it's mostly remnants from a cool RV repair shop that was super helpful. So of it I had to reprint white.

We ended up really liking the white accents on the mill finish aluminum. It was just a shot in the dark at first. Even repainted the fenders based on the success of the trim.

[mcubberley]

So I just had a bit of an epiphany. I am not really a "polishing" type of guy. I want to be because I love that glossy airstream look but I don't have the patience or will power for it. I tried mothers on a panel and that stuff works but that black goo is a nightmare. Gets everywhere and stains even the smallest scratch in the trim black. I do have some sweat stains on the panels from installation but I don't really know what to do about them. Can't just use mothers on a small spot because of how good of a job it does. I tried some turtle wax on the sides but that didn't do much other than giving it a nice smooth touch and should keep the water from hanging out and leaving water marks. We shall see. I might try the vinegar, water and dish soap mixture on one to see if that does anything. So many good suggestions on this forum.

Perhaps if I had a buffer and all the tools associated with detailing it would be different. Alas, I do not so we are going to let it age like a fine wine. I have other projects that will fill that time.

On the one panel I cleaned up I did add some finishing touches. Figured the look and feel of the trailer fit well with the aesthetic of one of my favorite series.



If you know the lore of the show "The Beacon" is how they find the island since it is always moving in space and time. The coordinates are some of our favorite places. We will keep wrapping them around the base of the tear as we go exploring. Note - Cricut brand vinyl is the worst. It used to be repackaged Oracle but they seem to have cheaped out over time. Do yourself a favor and order some good Oracle vinyl (cast, if you want the best Oracle 751 is lovely and totally worth it if you can find it in sheets. I like Beacon Graphics for bigger amounts) I was just in a pinch and it bit me.

Here is pic of the new river near Blacksburg just for giggles.

[larryl]

I'm going to try this method next to polish the aluminum,

https://www.youtube.com/watch?v=7kNIj2FS_7E


I have heard from others gives very good results.

[mcubberley]

I'm going to try this method next to polish the aluminum,

https://www.youtube.com/watch?v=7kNIj2FS_7E


I have heard from others gives very good results.

I wonder if that polishing wadding helps keep the black gunk from getting sticky as the polish dries a little. Mothers is fantastic but that black oxidation residue is a hot mess. I might go pick some up some of that wadding as well. Can't hurt too much more. :-)

[mcubberley]

I have hit my wall. 4 days of polishing, black goo, stainless cleaner, mothers wax, rinse repeat, sore arms, sweaty, dirty, cursing, smudging, cursing some more. In all, I would say I have 4 coats of mothers wax after polishing everything as best I could. I killed several rare paper towel trees, turned several fleece blankets black in the wash, and have aluminum oxidation permanently embedded in my fingernails. But I am happy with it and have drawn a line in the sand. I think I will stop rubbing it now and allow it to age gracefully from this point forward. At least I have pictures of it all shiny and new looking.