Aero-1, the build....

[Classic Finn]

Arne that is looking very nice.. Great start..

Thanks for sharing the photos..

Classic Finn

[Arne]

Thank you.. I'll be posting as I go.. it won't be fancy, but it will be insulated... I'm still working on the hatch design as I go... I can still go square back, but a tear drop shape is just more appealing...

I'm working with a full 4x8 sheet for the back so will move the door back some so the door hinge will fall on the seam... so many decisions....

And I have to call Grant and order my windows, and get the rough openings... should have done that last week... oh, well.

[Classic Finn]

Thank you.. I'll be posting as I go.. it won't be fancy, but it will be insulated... I'm still working on the hatch design as I go... I can still go square back, but a tear drop shape is just more appealing...

I'm working with a full 4x8 sheet for the back so will move the door back some so the door hinge will fall on the seam... so many decisions....

And I have to call Grant and order my windows, and get the rough openings... should have done that last week... oh, well.

Arne

Mine was supposed to be simple but as I go along I keep coming up with all kinds of different add ons... Is this a normal phenomenon or is it called being hooked on TD for life..

Classic Finn

[Classic Finn]

Finn,

I think it's called upgrade fever... What you'll finally end up with is the longest teardrop... refer to the Lucille Ball show, the long long trailer...



Mike...

Ive watched that film... its great.. So that,s what its called ...ok..



Classic Finn

[Arne]

There are so many nice-to-haves it is difficult to stop 'improving' the design..

The first one I built quickly in 2004, I think. This one, I've given a lot of thought to, and so far am off to a good start..

I tried to call Grant tonight.. here I am all set to start the walls, and I forgot to get the rough openings for the windows I want to put in... and I need those to get the framing right.... just slipped my mind....

I can guess pretty close, so I'll go ahead anyway...

[bledsoe3]

Arne, I like your website and the explanations of your progress.

[Arne]

Yes, I put more details on the web site since I share that with friends who are not forum members, and it also is all in one place. Here, with replies, things get kind of spread out.

But, I plan on putting the same pics here and there....

oh, I did finally talk to Grant last night and got the rough openings for the window, so am starting to profile the wall panels today..... finally feel like I'm moving ahead again...

First, I'll build the 8 foot section from the door hinge back to the galley.. that will be straight...

Then once that is up, I'll tackle the front.... the profile will be typical tear, but the side walls forward of the doors will also curve in... going to be tricky, but think I've got it all in place, at least in my head.. will be lots of sanding and probably lots of filling as all will be done free hand.

[Arne]

Formed the back part of the walls today. More on the web site...

I think I already have a 'too small' galley problem.... will study more closely tomorrow..

[Arne]

I must be making progress.. I ordered the cpes today...

I found a source for more buckets to weight it down with.. and the first side is almost studded out.. The YMCA get chlorine tabs in 6 gallon buckets.. each weighed 50 pounds, so they can take the pressure...

Once studded, I plan on trying to vacuum bag the opposing face on, so no brads.. I have locater pins to keep everything aligned... so far, no MAJOR screw ups, but the window frame is 1/4 inch off (forgot about the rear wall facing and measured from the stud... gonna take some work when I go to put the window in..

The experiments go on...

[Arne]

For a variety of reasons, little has been done on Aero-1 for several weeks... work, heat, humidity other obligations, laziness, etc....

The good part is the luan has given up the fight after 2 weeks with water buckets on it, and now lays flat...

And, I'm freeing up some time to get back to it.... flat ply, manna from heaven....

[Classic Finn]

For a variety of reasons, little has been done on Aero-1 for several weeks... work, heat, humidity other obligations, laziness, etc....

The good part is the luan has given up the fight after 2 weeks with water buckets on it, and now lays flat...

And, I'm freeing up some time to get back to it.... flat ply, manna from heaven....

Arne thats great news that youve won the battle of the luan .. The reasons for not moving forward has a familiar ring to it...

Now that the Daycare for our lil one is open again after its vacations.. I can really boogie on the Voyager as well..

Kind of got used to being Mr. Mom..

Classic Finn

[Arne]

I'm working on the walls and insulating them.. I'm running into a problem where the 1.5" insul is about 1/16" thicker than the studs so the inner wall won't sit flat on the studs....

I can rasp some of it down, but may have to try to hook the rasp to a 2x4 to get the wider places between studs....

I can't think of any good way to do this... I suppose I could try to build a hot wire, but that seems a bit extreme..

I'd like to get it flat with the studs, but am coming up empty, so am open to ideas.. should be something I can lay across the studs to cut the insul down level with the studs..

[Arne]

came up with a solution to my insul problem..

had to move frame and floor to another garage bay. bought 4 of these wheels at h/f last year.. finally found a use for them... 2 in back, one in front. Now I can move it around very easily until I get a torsion axle for it..

[Micro469]

came up with a solution to my insul problem..

had to move frame and floor to another garage bay. bought 4 of these wheels at h/f last year.. finally found a use for them... 2 in back, one in front. Now I can move it around very easily until I get a torsion axle for it..

And your solution is????

[Arne]

Since none of the individual insulated areas are that large, I will cut the pink foam into 4 inch strips... and trim the strips down the proper thickness on my table saw using the rip fence, then use the strips to fill the pockets.

With the door and 2 windows on each side, there is only one really large section, maybe 20x45 to fill, the rest are small. So, it will be a bit tedious, but doable.