Puffin 2

[steve wolverton]

If I remember correctly, on the Puffin 1, you had reinforcing strips (1x3?) running along the roof/wall joint. Have you gone without that entirely for this build?

That's correct. The sides/roof are bonded only by an epoxy fillet.

[steve wolverton]

and then there is "mirror clear" anodized which you can use as a mirror when shaving.

That is what I'm thinking I'm after for the next build. It will add quite a bit to the cost, but I think it will look fantastic.

Not to worry about the weight...a 4x8 sheet of .040 is about 18#. In Atlanta a 4x8 sheet of mirror clear is about $140 and is also available in 4x10 if that suits your build better.

I'm hoping I can pick it up in Austin or Houston for about that same price too. I'm willing to drive to Dallas if I need. Great post - thanks for the information!

[aggie79]

I'm hoping I can pick it up in Austin or Houston for about that same price too.

You might try here: http://www.regal-plastics.com/austin.html

[steve wolverton]

I'm hoping I can pick it up in Austin or Houston for about that same price too.

You might try here: http://www.regal-plastics.com/austin.html

I added them to my favorites. I'll give them a call when I start the next build. Thanks!

[steve wolverton]

Today was the day I've been dreading. Sanding. *sigh* I loaded up the mp3 player and ventured outside for hours of monotonous torture. 3 1/2 hours later I've finished. My arms are tired, my hands hurt, and they're bleeding.

The good news is 95% of the sanding is done! I used my longboard and got both sides faired. I have just a couple of areas that I need to add some epoxy ( a few screw holes weren't completely filled) and I'll be ready for paint!


Look ma! No shine.

Now I'm going to shower and try to get some feeling back in my arms.

[Mary K]

clippy.. my hands hurt, and they're bleeding.

You should turn the sand paper over and use the rough side down.

Just kidding.

WOW Steve that is a nice looking profile!!

[steve wolverton]

clippy.. my hands hurt, and they're bleeding.

You should turn the sand paper over and use the rough side down.

D'oh! Now she tells me!

[steve wolverton]

I made a phone call and found the insert roof edge, insert, & window drip edge. I'm going to pick that stuff up tomorrow. Roof edge is expensive. I've found it cheaper on the net, but this place wants $37.09 for a 16' section. C'est la vie.

I'll get that stuff tomorrow, and if all my parts make it on time, I should have the exterior of the camper complete by Sunday.

[WarPony]

Dude, you're killin' me with the bada$$ pace you're setting!!!!!!! Where did you get those glass balls from? I've been reading about them on the 'net and am REALLY interested in using them for an icebox project for my Widget. The whole epoxy scene is totally new to me and I'd like to try it on something small in case I goof up. I've got a bunch of screw holes to cover also. I used spot putty on some of them and it looks as if some of them are starting to pop out a little.

Good lookin' camper, man..............

Jeff

[steve wolverton]

Dude, you're killin' me with the bada$$ pace you're setting!!!!!!! Where did you get those glass balls from? I've been reading about them on the 'net and am REALLY interested in using them for an icebox project for my Widget. The whole epoxy scene is totally new to me and I'd like to try it on something small in case I goof up. I've got a bunch of screw holes to cover also. I used spot putty on some of them and it looks as if some of them are starting to pop out a little.

Good lookin' camper, man..............

Jeff

Hi Jeff. I got 3M ones from Ebay. I usually order them from Raka.

http://www.raka.com/filler.html

1 gallon for $8.50. Good stuff. They sand much easier than other fillers.

[john]

I remember you using fiber cloth on the cowper. Why not this time?

[steve wolverton]

I remember you using fiber cloth on the cowper. Why not this time?

Cowper had hardboard roof. The fiberglass was for extra protection (waterproofing). This build doesn't need it as it will be sealed with epoxy, and it will have a tonneau roof. If I were to paint it, I would have glassed it, but since I'm covering it with tonneau, it's not necessary.

[Esteban]

Steve, your Puffin II is looking great. I'm in awe how fast you're building it.

I have some newbie experience with fairing to share. I used Raka's epoxy mixed with red phenolic micro balloons to fill staple divots and low spots on my side walls. They were flat on a workbench while I fiberglassed and faired them. Before the epoxy and micro balloon mixture set up it leveled out quite a bit. It was a pleasant surprise that reduced sanding.

[steve wolverton]

Can you tell us more about air boards. What air pressure and how many cubic feet per minute does an air board sander require?

I have some newbie experience with fairing to share. I used Raka's epoxy mixed with red phenolic micro balloons to fill staple divots and low spots on my side walls. They were flat on a workbench while I fiberglassed and faired them. Before the epoxy and micro balloon mixture set up it leveled out quite a bit. It was a pleasant surprise that reduced sanding.

That's a good tip with the microballoons.

As for the fairing board, I wish I had an air setup, my sanding board is a regular 14" hand board. It's powered by me.

[Esteban]

Hi Steve, You answered before I edited out my air board question. A Google search on air boards showed they need considerably more CFM than my compressor produces. Looks like a hand powered longboard sander will be the final fairing tool to use. Mixed with some blood, sweat and tears.

Glad my newbie fairing experience was helpful. It was quite a pleasant surprise to come back hours later and see that the epoxy and microballoon mixture had leveled out. It spread out a little too. Near one edge it crept beyond where I applied it...wasting epoxy. "Next Time" in a similar situation I'd tape the edge with blue painters tape, kind of like a short dam, to contain the wet epoxy and filler.