Aluminum Frame RD

[RandyG]

So, I've final started doing something after lingering around the forum for over 8 months. The plan is to build a Camp Inn 560 rain drop design on top of a riveted aluminum frame. The frame will be .063" sheet metal bent into C-channel with some square tubing down the middle. Pics coming as soon as I learn to upload.

[RandyG]

Center length of frame minus the square tubing

12' piece light enough for my 6 year old

Rivet pattern- 6 rivets on each joint, may go with more later

Nice shop head, if I say so myself!

Never mind the color, it's the primers I used. It will get another coat of primer then some paint.
Shot 75 or so rivets before I ran out, will get more tomorrow as well as more C-channel bent up for the sides and additional bracing.

[RandyG]

Anyone know a dummy-proof way to make sure your frame is square?

[KCStudly]

Make the sides and ends exactly the same lengths (respectively) then adjust until the diagonals are exactly the same length.

You could also make a big plywood brace and/or using the 3/4/5 triangle method (measure 3 ft down one side, 4 ft across and connect the two locations at 5 ft).

Pythagorean formula for right triangle:
a^2 + b^2 = c^2

er go:
9 + 16 = 25

[Junkboy999]

Best way to make sure is good preparation. Cut all your parts that are the same in a Jig or a fixture. Cut
all parts first. Cutting your parts one at a time as you need then is the best way to screw it up.

Use a spacing jig or two equal sized temporary bars to hold you side rails the same distance apart. Clamp
everything first before welding ( bolting or riveting ) . Them measure diagonally from corner to corner.
Unclamp, adjust and measure again. Repeat, rinse and repeat if needed.

[RandyG]

Thanks KC, I knew that but went dumb for a minute.
I brought some more metal for the side length and supports from middle to sides, got it clamped together and decided to put it on the scale again. 13.9 lbs for a bare frame!!! Less than half of what I guestimated, And that's with 8 of the 1" spring clamps on it.

[KCStudly]

I knew that but went dumb for a minute.

Happens to us all from time to time.

[RandyG]

Got the ribs going from the middle out

Nice and square, those small triangle brackets will hold the nutplates for the plywood floor to bolt to.

Also took the kids to the Monster truck show, well... I'd probably go kids or not, FREE TICKETS!

No pic but I did get the sides temp installed with rivets in each corner. Everything is square but my corner-to-corner measurements are 1/8" off.
Since it's temp installed I'll look more into it, hopefully just some trimming will do the fix.

[RandyG]

Cool to see your kid is being part of the build, hope he enjoys the camping with you

Oh yeah, all three of them love camping, but just having a Chevy HHR doesn't give alot of room for gear.
Though a little young to rivet, afraid of the noisy tools, and getting distracted every two minutes they are really excited about the build.

[Junkboy999]

Hummm

Aircraft worker, monster truck.
McConnell? , Intrust Arena ??
Are you in Kansas Toto ??

hahaha

[RandyG]

No, northwest louisiana

[Lonnie Mac]

Center length of frame minus the square tubing
Rivet pattern- 6 rivets on each joint, may go with more later

Nice shop head, if I say so myself!

Never mind the color, it's the primers I used. It will get another coat of primer then some paint.
Shot 75 or so rivets before I ran out, will get more tomorrow as well as more C-channel bent up for the sides and additional bracing.

Watching this thread. Looks fun! Guess I can say I have bucked a few hundred (thousand) rivets or so!

I wonder about your rivet spacing though in this upper pic. 6 rivets in shear...

The bottom pic looks like a perfect 1 and 1/2 D. Good job!

[RandyG]

Yes the 6 rivets are in shear stress, I will go with more than six and the spacing is less than 1" staggered (T.O. 1-1a-8).
Thanks for the comment. I am going to make some progress this weekend and make lots of noise, more pics coming soon if my neighbors don't shut me down too early

[RandyG]

A lot of riveting this weekend and also got it squared off.
Frame is plenty strong.

And very light!

[RandyG]

Not much action this week. I've been planning lots though. I'm kinda worried about the twist the frame has in it. It has strength side to side and front to back but the whole thing will bend if stress is put on one corner. Will just the side walls and bulkheads beef it up enough? I was thinking of putting an 1/8" groove in the side walls and making the wall fit inside of it (dado joint). If I go with 1/2" ply for the walls and side, will that be strong enough? I want to be as light as possible but 1/2" seems thin to me with the 1/8" groove for the floor. Some input would be greatly appreciated. Just want to feel a little more confident before I buy $300 worth of wood.