TwilightLane Cubbie Build

[TwilightLane]

Somewhere along the way I insulated each wall. No pics of that for some reason. Totally forgot.

Here is a glimpse:

[TwilightLane]

After reflecting on how I want to assemble the side walls. I decided to build the walls so I can just lay the headliner in the top, on ledges, then installing the spars over it. The previous plan was to assemble the spars, then push the headliner up into it. After reflection and look at some other threads, it is apparent that must be a pain in the a$$.

So I need to make some changes. I need to create that ledge all the way around. To measure where the ledge should go, I made a little jig. It sure aint pretty, but it worked really well. I used a scrap of spar plus a little piece of the headliner (1/4 ply). I used a bigger piece of scrap as the rail that will slide along the edge of the piece. Finally a cap to hold the razor blade. I started to use a regular razor blade, but it shattered when I tried to attach it. Finally I used a utility knife blade held in place by an assortment of screws and nails.

Again, not pretty but it worked great.





Here it is in action.

[TwilightLane]

So I used the jig to mark where I needed to cut off the tops of the studs.



And after.

[TwilightLane]

Next step I wanted to work on the inside ply wall. I got two sheets of 1/4 ply. I lined up the two sheets and drilled a couple of screws. That will keep the sheets lined up. I've got the finished edges on the inside.

[TwilightLane]

My first cuts were to shape how I wanted the piece to end at the end of the wall, where the bulkheads kick in.

[TwilightLane]

I didn't get a pic of the next step. Here I laid one of the side profile pieces on TOP of my sandwiched 1/4 inch ply. I made sure the front of the bulge lined I lined up with the leading edge of the sandwich. And the bottom of the sandwich was two inches up from the bottom edge of the profile. I plan to have an 'upside down' ledge on the bottom of the wall. I then simply traced the profile.

That is only an intermediate step. I now matched the outer profile. But my ledge is smaller then that. Here the jig comes into play again.



Look close and you can see the line cut by the jig. And Aspen keeping an eye on things...

[TwilightLane]

Making sawdust.

[TwilightLane]

Here we go, the entire piece is cut away. It was so overcast, I had to use a shoplight to help me see the line.

[TwilightLane]

Here is the piece so far. I also traced the spot for the doors while I was at it.



You can see Tundra's ears as she is hanging out in front of the door!

[TwilightLane]

So here is the ply sandwich standing in front of one of the profiles. Psyched!

[TwilightLane]

Time for some glue. I bought a couple tubes of PL at Ace Westlake. Got home and BOTH were dried out. Kind of a PITA but Ace 1. exchanged them no questions asked for two new tubes and 2. were incredibly apologetic and even embarassed. Kudos to Ace.



Here it is braced together. I'm not trying to squeeze the hell out of it, just keep it in place as glue dries/cures.



I used plenty of wax paper under and on top of the piece to keep the glue under control.

[TwilightLane]

Looking at how I was going to build the bulkhead, I decided to add another bracket to hold the counter top. (That is that little horizontal piece). And finished the insualtion.

[TwilightLane]

Hatch cover. I'm not going to use any hardwear or even drill a hole. I think this notch will do the trick.

[TwilightLane]

Finally a glimpse of the profile. The tail is glued on. Here is what she will look like.

[Darren]

Thanks for the updates. It's coming along great.

When do you think you'll be ready for camping?