Benroy style dutchie (doors done)

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Re: Benroy style dutchie (doors and Wiley windows)

Postby teddy » Mon Jul 02, 2018 2:57 am

Hello guys and gals, it's been a day or two, but i'm building again. Financial and health problems kept me out of the shed for a while, but a few budgetary cuts here and there should make it feasible again, yay! The biggest change is swapping the sides to wood instead of alupanel, and a lot of small things add up aswel.

Anyway, my roof is waiting for me!
4mm (that's about 1/6") brushed aluminium panel.
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The sides all measured and cut,
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And primed.
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I hope to take her out camping this year, so the plan is "campable" not finished. all things needed to make her roadworthy are ordered, not as fancy as i want, but cheap and quick to assemble (lights below the trailer instead of build in the hatch etc). All things i can easily change/upgrade in the future.
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Re: Benroy style dutchie (roof done)

Postby teddy » Mon Jul 23, 2018 3:57 am

I slapped some paint on the walls.
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Mounted them,
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and added some trim. This took a lot of time, and i had to convince the aluminium with a hammer here and there.
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Next it was finally time to cut the roof to size and strap it on.
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And some trim around here too.
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Ooh, shiny!
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Next up, the hatch. Getting the locking mechanism together took some fiddling, it's a T-handle on the outside, an aluminium crosspiece on the inside, connecting to two 8mm (ca. 1/3") steel bars.
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Yesterday i started skinning the hatch, so i can trim it to size this week, and re mount it with some sealant.
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Re: Benroy style dutchie (roof done)

Postby teddy » Mon Jul 30, 2018 3:09 am

After skinning the hatch it was finally time to mount it!
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I've made some wooden supports to hold up the hatch during use:
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with little plates to prevent them from moving around. They are raised a bit from the counter top so i can slide a pin in the struts to prevent them from lifting, and its a lot easier to clean.
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Up on top its just small hinges, but the hatch rests on the struts, no force should be applied to the hinges.
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2 cupboard magnets hold the struts up when the hatch is lowered, as you can see i mounted the struts a bit staggered to ease the folding.
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Re: Benroy style dutchie (hatch done)

Postby KCStudly » Mon Jul 30, 2018 6:41 am

Looking good. :thumbsup:
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Re: Benroy style dutchie (hatch done)

Postby teddy » Sun Aug 12, 2018 1:07 pm

From here on out it's gonna be a bit of jumping around in time, i'll try to keep the story linear :-)

A few weeks ago you saw me adding a plate for the lock to the hatch, and drilling some elongated holes, here is the locking mechanism on the inside:
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The iron bars slide in to holes i drilled in the sides, i marked the holes by dabbing a grease pencil (otherwise known as eyeliner) on the ends of the rods.

And nothing but the best Chinesium uncle Ali has to offer on the outside:
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Now with the hatch done, it's time to make the hinge look pretty. The hinge itself is an ugly brown colour, and although it is waterproof, i'd want to make sure that nothing will reach it when driving or stationary with the hatch up. (it might leak in a bit when driving with the hatch up, but that would be quite a silly thing to do :lol: )
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My solution: Adding a strip of rubber in a hook shape over the hinge, mounted with two pieces of offcut from the hatch. The material is EDPM, or pondliner as it was sold to me.
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Next up, Doors! It is starting to get somewhere 8) First order, making some aluminium trimpieces for the doorframe.
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And presto! (times 2 ofcourse)
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Next the door itself: (note my hardwood clue stick, sometimes the aluminium needs a clue to where to go)
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The next image is redacted as it is me shouting and cursing because the door wouldn't fit the frame anymore due to me raising the doorstep a little. Long story short, removing the glued down trim piece and grinding off the stem of the T piece did the trick. Guess what happened on the other side? Nope, i remembered the doorstep, but the door was a little too wide, so, removing the glued down trim (i hate Sikaflex by now) sawing off a few mm (1/8") and slapping on some epoxy and paint and adding the trim again took some time.

Fits like a glove! Hinges added as well.
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Time to give the Wiley windows a little drain. Drilling a hole from the the inside corner angling down and a small aluminium tube coated in epoxy work nicely. Adding some sawdust to the epoxy to patch up the hole in the watertrench inside fixed that aswel.
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To finish it off i added the locking mechanism, a small stainless cover to hide the tube, and one on the venthole.
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The other side wont get an outside lock, just 2 cams on the inside. I have made the holes for the lock, so if i want to add it later i can do that relatively easy. I also added 2 gutters to keep the doors (seals) a little out of the rain.
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Four years ago when designing this tear i added an extra piece of wood in the sides to mount the fenders on, time to make some holes in it!
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Besides what i've shown here i did a lot of other little things, adding a D seal to the hatch, removed the interior lighting that decided to stop working in the last few years, cutting a million gaskets from the pond liner, adding more covers to more ventholes, etc...
It's been 2 weeks since my last update, but i finally get the idea i'm nearly finished. Next up, the driving lights, getting all the mains connected, and another gazillion small things.
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