THE Teardrop Explorer

[PubUltraStar]

You have a fantastic build. I'm happy to see you back on your project.

Thanks Tom. I used much of your build for inspiration, and always had your tongue box in mind when designing mine. Thanks for the tips on the A/C unit. I already have a splitter that will go in the headboard cabinet like yours, and terminate using auto vents. I haven't sourced those yet, but have tons of time to track those down. I found and ordered an adapter to attach to the downspout air return that converts to a 3" vent hose, so I think the only thing that I have to find is a suitable return vent with filter. Worst case, I'll use standard vent covers used in homes, and go without the filter.

[PubUltraStar]

Spent some time in the garage tonight getting some wood planed and ready to bend. Got the steam box out, and discovered that my second Earlex steamer had the connector broken off.



After the first one broke last summer, I had e-mailed Earlex inquiring about support and warranty, but never got a response so I just bought a second one. Now that this broke, I'm thinking that I need to find a different solution. I did email Earlex again, but am not very positive that I'll receive a response. Looks like my steam bending is on hold until I figure this out. I do have to work this weekend at the rescue station, and will be bringing some teardrop project work to do during my down time. I bought a dovetail jig last summer, and I plan on learning how to use that bad boy to create a nice tray for the yeti cooler to sit on. Baby steps.

EDIT: I did finally get a response from support, and they sent me 2 replacement units as they were covered under warranty. They basically told me that it was my fault that the units broke, and that I was using them improperly. I guess I need to be more careful, as the design on these is poor and prone to breakage.

[Shadow Catcher]

I would think it would be no trick to drill and tap the broken piece and install a brass/plastic nipple.

[PubUltraStar]

I would think it would be no trick to drill and tap the broken piece and install a brass/plastic nipple.

I definitely thought of trying that. I think that the trick would be getting a good seal on the curved surface that is drilled. Maybe a couple rubber gaskets.

[PubUltraStar]

I finally had a day off, and actually worked on the teardrop a bit. I received the 2 replacement steamers, so I thought I'd bend some wood! I hooked both of the steamers up to the box. Since the wood that I was using last year has been drying out in the garage all winter, I thought there might be some issues with bending. I decided to soak the wood after planing for a week in a long PCV pipe, before putting into the steamer. This wood was even more pliable and bendy after coming out of the steam box.



Using 2 steamers, the temperature inside the box got to 212 degrees. Hot!


I was able to get boards on all 3 molds.


My goal now is to have wood soaking in the "soak tube" while the wood on the form is drying. That way, I can steam wood that's been soaking about once a week as the bent, dry wood comes off the form.

[PubUltraStar]

I only have a couple of strips to go to finish the bending for the Tongue Box. Each level takes about a week in the mold after steam bending, so it will be done shortly. I didn't want to wait so I started sanding. Each layer is slightly different in thickness, and they don't necessarily make the corners exactly the same. By design, I knew that I would have to do some sanding to get everything smooth.



My little buddy checking out the progress


I did some testing of filling the gaps with some wood putty, but I don't like it. I have removed all of it after this picture was taken. Since the wood that I bought was green and unplanned, it wasn't exactly true on the width either, which is why there are different sized gaps. I'll fill them with epoxy when I am done sanding and ready for fiberglass.

[BuildingForFun]

Thanks for the information, I think I'll rely on the welds alone. I won't be able to work on the tear this weekend, so I got some wood bent on the template. It's amazing how may clamps I've accumulated for his project. Think you have enough clamps? Nope, you need more clamps.

Here is my template clamp pile. Sadly, this isn't all of them.

Oh my,.....you just discouraged me....guess I will be headed back to Harbor Freight.
My build. viewtopic.php?f=50&t=60533

[BuildingForFun]

I Guess you have so many for forming the wood though?

[PubUltraStar]

I Guess you have so many for forming the wood though?

Yes, mostly for steam bending and clamping those boards. I wouldn't need 90% of these clamps if I wasn't bending.

[PubUltraStar]

Finally got to spend the day last Saturday getting the pieces I needed cut on the CNC machine. This includes the forms to create the raingutter above the door, the form to create the tongue box lid trim, and the molding for the inside and exterior of the doors. It was all cut out of Birch Plywood, and hopefully, I'll have a couple of nice weather weekends to put some time into it.



This is one set of the exterior door trim. You can see on the one there is shape extruding for where the Stainless hinge will be mounted.


Unfortunately, life has been busy, and the teardrop has been a lower priority of late. I'm planning on moving the steam bending into the basement for the winter, so that I can keep moving forward. I did take another photography vacation to Glacier National Park recently, thus reminding me how much I need to complete the teardrop.









More pictures can be seen here: http://www.m2-photo.com/Travel/National-Parks/Glacier/Glacier-2014/

[KCStudly]

Very nice pics!

[_Ryan_]

Can't wait to see more updates!

[HarryL]

Welcome back!

[PubUltraStar]

Although it's getting really cold here in Wisconsin, I've made the commitment to keep work on the teardrop as I can, and have some space in the basement to keep steaming. I've recently got a ton of new parts, most of which I won't need for a long time.


- Porch Lights
- Brake Lights
- Interior Dome Lights
- License Plate Light
- Galley Strip Light
- Galley Accent LIghts
- Marker lights
- Switches
- Chrome access doors for Tongue box

Not Pictured:
- Windows for Doors
- Stargazer window

[Gunguy05]

Just curious, where did you find the porch light.? I have been looking for some like this.