In general, progress is slow for me on this build. I would love to work faster, but usually half of my time is spent setting up or tearing down shop. I was hoping the garage I was borrowing this weekend would make progress increase, but two days just isn't enough time -- I still spent about half my time setting up and tearing back down...
But, I digress. Progress is progress.
Saturday:
I met with Bruce to talk about trailer brakes in a suburb outside Atlanta. He was an awesome guy, and provided me with plenty of helpful advice. He also thoroughly convinced me to get brakes, with his horror-story about him, a utility trailer, and a small tow vehicle. Thanks again for your help Bruce!
I arrived at my fiancee's parents' house at around 11am. I unloaded and started work.
I laid out my luaun on the garage floor to trace out my profile:
And powered on my netbook to load up my 3d renders:
Then started measuring in the virtual world:
To put on wood in the real world:
And then take those measurements, ripping them with a jigsaw into the shape of the profile:
Finally, ending up with the end profile in a template form:
Then, trace out from template to more pieces of luaun:
And cut until you end up with 16 panels -- 8 for each wall (4 inside and 4 outside):
I laid out one set of the profiles, and mocked in the window so that I could plan the internal wall structure:
And started placing 1x3's down that will eventually be secured to the luaun:
I pulled out my new toy (Kreg pocket hole jig!) to secure the verticals to the horizontals.
Eventually, I came up with this:
Then moved on to tracing the outer edge with custom-cut pieces (which took FOREVER):
About halfway through the framing, I went to sleep.
Sunday:
I finished with the frame:
Next, I started my insulation:
Maddie and Sophie helped:
And suddenly the insulation was done:
Since the side below the framing had all the markings on it for the window locations, I carefully slid it out and laid the luaun out on top, on the exact same location as before:
Once that was glued (liquid nails) and screwed (about 50 3/4" screws), I flipped the wall assembly over. At this point, the wall was a bit flimsy. It had a bit of a wobble to it, but held together well.
I attached the other side using the same method, and propped the wall up. The window hole was cut out, meaning the basic frame of the passenger side wall is DONE!
Phew, that took forever.
Not quite enough time to do the other wall, so I decided I would go ahead and make the wheel wells:
Which didn't take long:
Time to pack up... I had to transport the wall somehow, so I built up a quick frame to lay the body on. All my extra wood, along with the drivers side wall panels went underneath:
I had a hunch that it was going to rain earlier than the forecast stated, so I secured everything with a tarp. I moved the tarped trailer outside and hooked it up to the car, so we'd be ready to leave after dinner with the parents. Good thing too -- it started raining during dinner, and was soaking the whole way home. I wrapped it well, and everything stayed high and dry.
My parents are going out of town tomorrow, and have volunteered their garage for the week. I will be busy tomorrow, but Tuesday-Friday should be major build days for me.
