Need Notch Knowledge

[DudKC]

We got the outer wall cut out today. Here is a pic of the shape we are going with.



I am roughly trying to follow the generic benroy plans found in the header links above, and now we need to cut the notch out of the hatch end of the wall. According to the plans, you are to cut a 3/8" notch from the wall starting just aft of the final roof spars. We aren't really following the plans using the same measurements as the generic, so how should I determine how deep the notch needs to be? I plan to skin the front, roof, and hatch with one layer of 1/8" birch, or one layer of 1/4" birch if we can't find 1/8" anywhere, if that info is helpful.

Thanks for the help on this fine holiday weekend!

[madjack]

...some thoughts...1/8th ply can be hard to source...the big box stores often have all wood(usually birch), 1/8th interior paneling...this is a pretty good substitute(with well sealed edges) and I have used it in the past with good results...keep in mind, the finished side usually can't be easily/reliably glued to anything else due to the finish on it...

...the notch...if the roof and hatch are skinned the same, that material does not need to be included in your figuring...the notch should be able to accommodate your trim(if applicable) and 50% of the thickness of your seal material...in other words, if you have a 1/16th of trim thickness and a 3/4"thick seal, the notch would be approximately 3/8th...basically figure to 1/2 the thickness of your seal material............
madjack

[DudKC]

http://www.lilbear.teardrops.net/parts.html#seals

Thanks, Madjack! So if I was to go with a hatch seal like the above which is somewhere between 6 and 7/16", and I would only need to notch out between 3/16" and 1/4"? This is assuming I skin the hatch and roof with the same thickness ply.

This leads to an unrelated question. If I go with 1/8" for the front and roof, I wouldn't need to recess my roof spars right? If I go with 1/4" ply for front and roof, would I need to recess my roof spars a 1/4" so the roof sits flush with the side walls? Or am I wrong and I need to recess the spars even for 1/8" ply on the front and roof?

[dh]

I would make the spars flush with tops of the walls. Let the roof material actually hang off the sides a bit, and trim with a router and a trim bit after the glue cures. If you used 1/4'' for the roof and 1/8'' for the hatch, calculate the gap per MJ's instructions, and reduce by the difference in material thickness. If using 1/8'' on the roof, and 1/4'' on the hatch increase the notch by the difference in material thickness.

[3822sean]

looking good ,,,50% is good advice

[madjack]

...yes, on the notch...keeping in mind to add in for any trim on the edges of the side wall or edge of hatch(if any is used)....

...as dh sez, put all spars flush with the edge of the side wall and lay your roof ply directly on the spars and edge of the side wall.............
madjack

[exminnesotaboy]

I plan to skin the front, roof, and hatch with one layer of 1/8" birch, or one layer of 1/4" birch if we can't find 1/8" anywhere, if that info is helpful.

Shutte Lumber down on Southwest Blvd has 1/8" birch, but I believe they only carry it in 5'x5' panels. We found 1/8" birch in 4x8 foot sheets when I built mine in 2005, but that place has since closed.

[DudKC]

Thanks for the wood tips! Menard's in St. Joe had 1/8" lauan which seemed to bend ok. I know other people have used lauan, I would rather go with birch for looks so I'll probably hit up some lumber yards around town for some 1/8" birch before I go with the lauan. Or do you think my 2nd choice should be the 1/4" birch? I think we can bend the 1/4" birch and I like the looks better....