Pikes Peak Woody Build

[badschnauzer]

Your interior looks fantastic. Was it difficult to bend the planks around the radius? I have to admit I'm a bit jealous. Good work keep it up!

Thanks. I didn't bend the planks. My attempts to cut kerfs on the back and bend them met with failure. My alternate was to shave off some of the tongue on each plank so there would be some give in the corresponding groove as I progressed around the 19" radius. Easily done and I like the profile.

[badschnauzer]

Major milestone completed today; the exterior plywood sheets are now permanently attached. The wiring is now permanently ensconced inside the wall sandwich (1/4" ply - 3/4" blocking - 1/4" ply) and I'm through with adding any "just in case" blocking. I applied the first coat of poly 2 days ago. It was a bit gusty but I figured I could spray OK between gusts. I managed to apply the Gloss Spar Urethane (oil based) with no issue but when I set the sheet aside to dry, the wind kicked dust and debris into the wet poly and royally screwed it all up. I set the sheets inside the garage, let them dry and lightly sanded them next morning. Yesterday was less windy so I was able to get three more coats of poly on before letting it dry overnight. It looks great! Nice depth with a smooth, glossy feel. The HVLP sprayer from HF works like a champ - easy set-up (slightly diluted poly with mineral spirits), consistent application, and easy clean-up. Balls deluxe.

These pix show my spraying station and the final product drying in the sunshine. The blue tape kept poly off the areas where the PMF will overlay the edge.



I permanently attached the outside sheets this afternoon. Applied PL Premium to all the blocking, screwed the perimeter (will be covered by wood trim) and placed clamping cauls to hold down the field. I also ran my trailer 7-wire and battery wire through some 1" PVC conduit from my galley junction box to the front of the TD. My TD battery box will be housed on the trailer tongue to even out the weight distribution. Finished up some trailer marker wiring before calling it a day.



Overall, I'm happy with the progress. Good weather has helped immensely. Next steps are prepping for sheathing the roof, build doors, and construct the hatch.

QUESTION: I want to shave 1/4" off my sides in the hatch area to better fit the gasket material. Whats the best way of doing that? Belt sander? Router (how)? Thanks!

[KCStudly]

Progress looks great!

The best way to trim the galley wall edges and still maintain your profile would be to use a rabbeting bit and cut about half the thickness of the wall, then come back with a top bearing bit (with the bearing rolling on the rabbet cut) to take the other half of the wall thickness. You might want to do this in two or three passes rather than one big cut.

Tom (aggie79) demonstrates the technique in his Silver Beatle build thread here.

[badschnauzer]

Progress looks great!

The best way to trim the galley wall edges and still maintain your profile would be to use a rabbeting bit and cut about half the thickness of the wall, then come back with a top bearing bit (with the bearing rolling on the rabbet cut) to take the other half of the wall thickness. You might want to do this in two or three passes rather than one big cut.

Tom (aggie79) demonstrates the technique in his Silver Beatle build thread here.

Perfect! Just what I was looking for. Flush trim bit ordered and will be here Tuesday.

BTW, I used one of your pro tips today: hotel card key as a PL notch trowel. Worked like a champ. Thanks, KC.

[KCStudly]

No problem, I'm sure I "borrowed" that from someone else.

So you already have a rabbeting bit with various roller bearing diameters?

[badschnauzer]

So you already have a rabbeting bit with various roller bearing diameters?

Doh! I meant to write rabbeting bit (with multiple bearings). I already own a flush trim bit. It was getting late...

[KCStudly]

Just watching your back, dude.

[badschnauzer]

Double Post - deleted.

[badschnauzer]

Busy days applying the outer skin. 4' X 8' sheets of 1/8" luan glued with PL Premium and stapled with crown staples. I started with the front flat section; easy peasy. Took a few staple shots to get the right compressor pressure. Too high and they'd blow right through the luan; too low and it's hammer time (don't stop!). I was woefully unprepared for the curve. I glued up the 4' section encompassing the front 17" radius curve and popped a few staples into the leading edge. Once I started to make the turn. those staples blew out the luan. Oh no. Running around like a one-armed paper hanger, I managed to screw a few blocks onto the leading edge, find my cinch straps, collect a few 2X4 cauls and start working the luan around the curve. Much cursing, cinching and stapling later, I managed to get it down within the PL's working time. Everything is holding after removing the straps and it looks good.



QUESTION: What do I use to fille the seams and staple holes? Regular speckle or is there some other preferred joint/fill compound. I'll be applying PMF with TB II if that matters.

Tomorrow I start the hatch. Yippee!

[ELM]

looking great. When I'm working with wood that I'm going to paint or cover I use auto body filler AKA Bondo it sticks to the wood great and is easy to work with. There's my 2 cents. Keep up the good work.

[badschnauzer]

looking great. When I'm working with wood that I'm going to paint or cover I use auto body filler AKA Bondo it sticks to the wood great and is easy to work with. There's my 2 cents. Keep up the good work.

ELM, I've read that TB II does not adhere well to Bondo. That would make gluing the canvas on the luan difficult. True?

[ELM]

looking great. When I'm working with wood that I'm going to paint or cover I use auto body filler AKA Bondo it sticks to the wood great and is easy to work with. There's my 2 cents. Keep up the good work.

ELM, I've read that TB II does not adhere well to Bondo. That would make gluing the canvas on the luan difficult. True?

I haven't heard that. Sounds like it would worth testing some first. I have bondo and TB II and III. When I get back home I will test it and see what happens. I'm at Yosemite for a few days.

[badschnauzer]

looking great. When I'm working with wood that I'm going to paint or cover I use auto body filler AKA Bondo it sticks to the wood great and is easy to work with. There's my 2 cents. Keep up the good work.

ELM, I've read that TB II does not adhere well to Bondo. That would make gluing the canvas on the luan difficult. True?

I haven't heard that. Sounds like it would worth testing some first. I have bondo and TB II and III. When I get back home I will test it and see what happens. I'm at Yosemite for a few days.

ELM, I tested regular wall spackle on the luan and checked to see if the TB II will stick. No issues. It's super easy to work with and dries in no time. Most of my seams are tight anyway so there's not a lot of filling required. I'd still be curious to hear what you discover about the bondo.

Enjoy Yosemite!

[badschnauzer]

Another beautiful couple of days and more progress. I prepped the TD for the canvas covering. Filled all the staple holes and gaps with regular wall spackle. Sanded them smooth and went over the entire TD with a moist sponge. I then draped my 7 yards of canvas over the top/front of the TD and cut it to size with about 12 inches extra length. The duck cloth is from Big Duck Canvas; I ordered the #12/72 "Plied Yarn" which has a tighter weave which makes it stiffer and more durable. It looks great. I haven't glued it to the TD yet so I can't comment on that aspect. I hosed it down on the patio to pre-shrink it. The water beaded up at first until I worked it in with hose pressure and running my hand over it. Rolled it up and it's ready to go.



Started on the hatch while the canvas dried. Used a rabbeting bit and a flush cut bit to take 1/2" off the galley wall profile. What a mess. I made 4, 1/8" passes to achieve that depth (4 rabbets, 4 flush cuts per side). There was some awkward positioning of the router as I had to cut against the rotating bit. That's a total of 16 chances to screw up my walls. It came out well with only a minor nick in a inconspicuous location. The garage was covered in dust/shavings - I wish I had done it in the driveway. Afterwards, I cut some hatch ribs using my original hardboard template, rough installed the hurricane hinge and made preparations for the hatch build.



The galley storage covers are also partially completed. I made them up as cutting boards but they also act as covers for the reach down storage. Still need to be sanded and oiled. Finishing the boards and drawer faces are all that's left to do in the galley (sans hatch). Sweet!



With the nice weather, I'm leaving the garage door open while I work. The neighbors are getting curious and they're taking more walks than usual up/down the alleyway. I invite them and show them what I'm building. I've met 2 neighbors I hadn't know previously. Good fun.

[KCStudly]

Great work! Those cutting/drop in boards look awesome! Can't wait to see them with some mineral oil on them.