My build of Benroy Style Trailer

[AlgoDan]

Ok got my Galley latch mounting plate cut and fitted for the latches..next I will start the hinge and strut mounting....

[KCStudly]

Is that two slam latches set into a trim plate?

I don't think I have seen that before, but it should work okay, yeah?

[AlgoDan]

I figured I wanted some good strong base for mounting with rivets, the plate will be placed on the lower portion of Galley hatch and then skinned with Aluminum. They are T-handle latches not slam latches. They should work, better than screwing into wood....

Is that two slam latches set into a trim plate?

I don't think I have seen that before, but it should work okay, yeah?

[KCStudly]

Thanks. I think I get it now.

I like the idea, and your craftsmanship looks first rate.

I'm just trying to understand that style of latch (I have not worked with those before) and how they will be able to compress your seal. I wasn't familiar with the T-handle style latches, so I looked at some detailed images of them on e-trailer. It looks like the handle end acts like a cam to pull on the latch stem along with the locking cam, giving a draw tight feature.

It seems like one of the problems some people have with the traditional cross bar style of turn latch (with one handle located in the middle of the hatch) is that they don't really have a way to draw the hatch down into the seal. I can invision those setups being awkward: push down on hatch and try to turn the handle so the pins both engage at the same time. Might need three hands, one to push on each side and another to turn the latch.

With your design, you can push and latch each side independently, so that is a big plus. At least that is how I see it in my minds eye.

I like it.

[AlgoDan]

Thanks for the kindness. Yes the T-handle latches I bought through e-trailer. I have had the cross bar style before with a slam latch, you are correct the seal is not as tight as the T-handle latches. I figure go with a tight seal and security. Cheers

[AlgoDan]

Test mounting jig
Ok today I was testing Hatch strut location mounting and load ratings. Hatch weighs 24lbs. At first mount on hatch at 7'' Hatch weighs 46lbs.with 2-30lb struts door will stay up but light to the touch. Will likely exchange for 2-50lb struts...trial and error, always learning....will post what works the best. In the photo I set up a mounting jig half ass with the hatch, as not to drill to many locating holes in the trailer. The hatch will get skinned with aluminum when location is bang on....

[Junkboy999]

Look really good

I take it the aluminum around the galley hatch and the side wall are two different pieces?
I’m curious on how the back edge and the sides meet and gets sealed.

Do you have a metal break? Those folds looks great.

[AlgoDan]

Thanks for the compliment....Yes the Aluminum trim are seperate pieces, they are done in shingle fashion overlapped joints. They will get fastened with a caulk sealer on each lap joint and screwed in 90 degrees of the face and on the outside edge. As for the bending/forming its done at work with a 90 Ton Brake Press.

Look really good

I take it the aluminum around the galley hatch and the side wall are two different pieces?
I’m curious on how the back edge and the sides meet and gets sealed.

Do you have a metal break? Those folds looks great.

[91kuhndog]

Nice build Dan... I think I'm going to go with that square back design as well. My original plans were going to use the Benroy sloped galley but from what I can see, I'd be giving up a lot of space in the galley. That's awesome though.

[AlgoDan]

Thanks for the compliment 91 kuhndog...Yes the square back was planned for more storage as we pack lots of gear for our trips...

Nice build Dan... I think I'm going to go with that square back design as well. My original plans were going to use the Benroy sloped galley but from what I can see, I'd be giving up a lot of space in the galley. That's awesome though.

[AlgoDan]

Ok went with the 56lb.-23in. struts.Wow way to stiff, mind you the mount was just shy of center on the hatch, put a tremendous load on the mounts....Next exchanged them for 46lb.-17in. struts and wow hit the sweet spot, Mounted 7in. from hinge out to Galley hatch and 17 in. down on wall mount...all in all in total 4 sets of struts tested. Now get ready to mount the Hatch for a test fit...

Test mounting jig
Ok today I was testing Hatch strut location mounting and load ratings. Hatch weighs 24lbs. At first mount on hatch at 7'' Hatch weighs 46lbs.with 2-30lb struts door will stay up but light to the touch. Will likely exchange for 2-50lb struts...trial and error, always learning....will post what works the best. In the photo I set up a mounting jig half ass with the hatch, as not to drill to many locating holes in the trailer. The hatch will get skinned with aluminum when location is bang on....

[AlgoDan]

Ok more pics of galley hatch/latch prep work....


The inside will get a cover over the striker for a finished look. They stick out because the face of the door will rest on door stop which is part of the aluminum door frame.

Ok got my Galley latch mounting plate cut and fitted for the latches..next I will start the hinge and strut mounting....

[KCStudly]

Cruising right along! Keep on keeping on!

[AlgoDan]

Ya always a plenty to do with building the trailer, no shortage of items to cross out.....

Cruising right along! Keep on keeping on!

[AlgoDan]

Ok next stage of build is Roof/wall moulding trim. I have searched high and low for it, I would need to order from the U.S , I would get raped by UPS on shipping/duty... So I thought of going with outdoor PVC...Went to Homer Depot last night picked up some PVC trim moulding for windows. So I picked up a piece of 12ft.long at $15 per.length. This stuff is light ,flexible, wont crack so hey give it a try! Comes in white only but is paintable. It cuts nice, drills and countersinks great. So I did a sample piece, had to use table saw to cut the profile I wanted. I did a piece with and without radius edge. The router leaves somewhat of a rougher finish, perhaps maybe two passes would help.... Anyhoo a few pictures posted of a sample and a fitted piece on the front radius of trailer..Let me know what you think. Cheers



Profile with and without Radius

Clamped on at the Radius


Also dimensions of the finished Moulding is 1.6 Wide X .670 High X .200 Wall