A Question for the router gurus

[Larwyn]

After receiving my hatch hinge (from Grant), I now realize that the wall in the hatch area needs to be trimmed. Either that or the hinge shimmed up.

My plan for trimming this area is to make two (or more) passes with a router. The first operation will be with a rabbit bit, the second with a flush trim pattern bit (top bearing). Of course the ends of the cut will have to be squared up with a chisel. One problem I see with this approach is that the rabbit bit takes off 3/8” of material, I was thinking ¼” would be plenty. The wall thickness in the area to be cut is 1”. Does it sound feasible to attach 1/8” aluminum across part of the wall thickness to act as a shim under the bearing of the rabbit bit thereby decreasing the depth of the cut to ¼”, then removing the aluminum shim and making the pass with the pattern bit. Or would it be just as well to take off the full 3/8” and make up the difference with trim and rubber seal?

I’m sure if Steve Fredrick sees this he will advise me of a better way. I hope…

[rjhager]

Larwyn,

My KuffelCreek Comet plans call for 3/8" to be taken off that area for a flush (aluminum skinned) fit.

Hope that helps.

Randy

[Larwyn]

Larwyn,

My KuffelCreek Comet plans call for 3/8" to be taken off that area for a flush (aluminum skinned) fit.

Hope that helps.

Randy

Great..!!! Yes that helps a LOT..!!! That will simplify the trimming, not having to deal with temporary shims. Thanks for the quick reply.

Building without plans is a bit of a challege at times. But this forum always seems to come through with the best help available.

[fornesto]

Don't worry too much. I accidentally took 9/16" off. With a heavy weatherstripping now in place, its hardly noticeable. It actually gives me a little more room for compression of the weatherstrip.

[SteveH]

Larwyn,

When I built my trailer, I didn't use plans either and did not trim the walls in that area.

What I did was when I built my hatch, I built the ribs the same curve/size as the walls, covered the frame of the hatch with 1/4" ply that did not go past the hatch frame, and then installed a 1/8" X 2" aluminum molding from Lowes on the hatch that stuck out over the walls, and then put the rubber seal in between to fill the gap.

Sounds complicated, but it was easy. This is how it looks:

[exminnesotaboy]

Larwyn,

My KuffelCreek Comet plans call for 3/8" to be taken off that area for a flush (aluminum skinned) fit.

Hope that helps.

Randy

Before you just cut the 3/8" off(like I did already), make sure that it accomodates the "hurricane" type hinge you plan on using. The reason I mention this is that I *believe* that the KC plans use a hinge with an offset. But the new hinge that I just received from Grant at Lil' Bear has no offset. If you go to "Denny's Teardrop" in the Hall of Fame, he articulates this clearly on one of his pages.

Unfortunatley, I haven't gotten down to figuring out my hatch and if the 3/8" that I already cut out will work, so I can't provide any more insight - but you may want to look at it a little closer before you cut.

[Larwyn]

Exminnesotaboy,

Thanks for your comment. The hinge I got from Grant has no offset, The hatch leaf of the hinge has a downward protruding flange that apears to require a bit over a quarter inch of relief if it is not removed at the points of interference (the walls).
Looks like your 3/8" should work fine.

SteveH,

Did you use a hurricane type hinge. If so, did you simply cut the hatch leaf to match the hatch and the body leaf to fit the body? Or maybe notch the hatch leaf of the hinge over the walls to help divert water? Any leaks ? I had planned to build my hatch much the way you did yours. It is the hinge issue that has provided the opportunity for mental exercise (sit and stare, tape in one hand Guinness in the other).

[exminnesotaboy]

Looks like your 3/8" should work fine.

woo hoo! preliminary mental measuring tells me you are correct - otherwise I will be trimming, trimming, trimming

you know, I would get so much crap from my friends for wearing a kilt, but dang, it looks sooooooo comfortable to work in

[Larwyn]

Looks like your 3/8" should work fine.

woo hoo! preliminary mental measuring tells me you are correct - otherwise I will be trimming, trimming, trimming

you know, I would get so much crap from my friends for wearing a kilt, but dang, it looks sooooooo comfortable to work in

The "crap" only last a day or so, the FREEDOM lasts a lifetime. Besides, one reason it is called a kilt is "cause we done kilt everybody who called it a skirt.... " I have several kilts two like the one in the avatar, they are th most comfortable work clothing I own (unless I am welding ). They are also great for just relaxaing and drinking a beer... . Give one a try, you will wonder why anybody ever decided to put a 4 layer seam "there" in those jeans......

[SteveH]

Larwyn,

I got my hinge, a teardrop non leak type, from George at the Teardrop Fixit Shop in Montana. It is just like the one you have except it doesn't have the vertical aluminum parts. It is flat like a normal hinge.

My hatch does not leak at all. I was in a major thunderstorm coming back from Louisiana last Sunday and no leaks.

Wish I could say the same for the door!

[Larwyn]

Larwyn,

I got my hinge, a teardrop non leak type, from George at the Teardrop Fixit Shop in Montana. It is just like the one you have except it doesn't have the vertical aluminum parts. It is flat like a normal hinge.

My hatch does not leak at all. I was in a major thunderstorm coming back from Louisiana last Sunday and no leaks.

Wish I could say the same for the door!

Good deal, I should be able to just trim off those bits that are in my way and go back to my original plan. Did you have much trouble forming that 2 inch angle? I'm sure you must have anealed it. My hatch will be much flater than yours but any hints on forming that 1/8 x 2 angle would be appreciated.

Sorry to hear about your door leak. Let us know what you figure out on that one so the rest of us might avoid that problem. I believe I could learn to hate a soggy mattress.....

[SteveH]

Larwyn,

The 2" aluminum is not angle, but flat 2" X 1/8". No problem bending. I just put it over my knee and bent it.

[Larwyn]

Larwyn,

The 2" aluminum is not angle, but flat 2" X 1/8". No problem bending. I just put it over my knee and bent it.

Oh, I see. Yep flat aluminum would be easy to bend, no anealing and be plenty stiff for the seal as well as not being a reverse scoop to catch rain as you drive. Don't know why I assumed it was angle. I really like the way that looks. I will probably copy that idea. That flat bar will probably be straighter on my hatch than when carried flat at the balance point....

It'll be while before I actually start my hatch but with this info I think my doors will be a bigger problem than the hatch. Thanks for the answers. I'm sure we will meet at some future gathering of Texas Teardropers...

[DestinDave]

Larwyn.. I wore a "formal" dress kilt to a Christmas dance in Brechin, Scotland many years ago and, yes, it's very comfortable although a bit cold in a Scottish December... Have always thought about having one made to wear to Highland games or gathering of the clans in North Carolina (I'm descended from the McLeods of Skye). However I don't think I could get away with wearing one all the time. And when relaxing at home, I prefer more freedom than a kilt...

[SteveH]

I'm sure we will meet at some future gathering of Texas Teardropers...

Larwyn,

I'll be looking foward to it.