The No Tears Teardrop Build

[dales133]

Yea ive got one of those small agms i use in my boat and ive used it for testing wiring too.makes life much easier

[Diemjoe]

I appreciate that knowledge sharing. I do have to get the tape before I get busy on the aluminum. The wiring issue could have been prevented if I had better control of my cabling so lesson learned. Thanks

[dales133]

Look on the bright side,you mightnt have found the problem as early as you wanted but it could have been alot worse.

[Diemjoe]

I hear that.

[Breytie]

Those little 12V SLA make wonderful lanterns when paired with a piece of LED strip-light.Or any other 12V LED light for that matter!

[Diemjoe]

I see serious progress ahead. Roof is patched

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and aluminum has arrived

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.

[Diemjoe]

Wow, I hate working with steel.
I ruined the first sheet of aluminum my cutting too big of a notch to make room for the trim screws. There was a small 1/8 " gap at showing at a spot between the trim piece and the aluminum that I couldn't live with. The skin was a little off center and I didn't realize it. That was my first mistake. So I scrapped that piece and ordered another.

For the second effort, I decided that the neighbors would have to put up with 10 feet of aluminum cutting with the grinder. It took a few passes since I was a bit shy with the grinder. I didn't want to mess up another sheet. That was successful and had the trim holding it in place by the end of the day. I got up early the next morning and cut out the holes for the skylight and fan. That is when I made my second Mistake. I cut the hole to match the square skylight frame cutout instead of the oval skylight trim ring. The neighbors heard some choice commentary when I realized that happened. I just couldn't start over with a new sheet so I improvised.

I spent the rest of the morning cutting out an aluminum trim ring to cover the gap. It isn't pretty but it doesn't look horrible. I attached it with butyl tape and since the profile curve was going to cause the sky light to not really fit right anyway, this solution might solve that problem. Some day, I'll fix it.

The Square Cut

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When a round hole would do

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Not a pretty result

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[Diemjoe]

I'll get a close up of the solution once the solution gets pretty enough for a close up. In the meantime, here is a wide angle of the status.

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[rebapuck]

Looks great to me.

[Diemjoe]

It has been a while since I checked in and figured I better do so or you all will think I gave up. It is true that I have lost lost a bit of steam, i am at a point now where there is not that much changing that a photo really shows anything.

It was a battle but I did finish all the trailer towing lighting, the awning lights and the reading lights. That was a lot of work to get them all working at the same time but I have the roof permanently attached so let's hope the lights stay on (or off, depending).

I attached the hatch via the hurricane hinge. I attached the hinge without the door on and realized later that that was risky. It would probably be better to attach the hinge to the door then attache the hinge with the door in place so that that any errors in alignment could be fixed by adjusting where I attached the hinge to the roof. Luckily, everything seems to be straight and true.

There is a Gap between the door and the wall trim towards the bottom 1/3 of the curve. That has me perplexed but I think that I'll just add thicker weatherstripping to cover the gap.

I am now working on the cabinetry. I am using some maple we milled from a downed tree several years ago. it i a bit warpy but the grain has some personality so I am fighting through it.

The rains have come to Seattle right on time. Slowing me down a bit since i have to work in the cramped garage with all my tools and supplies under foot.

Pictures are coming soon.

[Diemjoe]

Time is already flying this year. Still slow going with the Seattle rains and house projects to keep up with too. I am happy to report that I am dangerously close to having the galley completed The PD4045 is installed and all of the lights and outlets are working. Still have some finishing touches but that is a big one. I do need to decide on what to do with my propane tank. I was hoping there would be more room in the galley. I am a little worried to store it in the cabin anyway in case there is a slow leak. I may be back to running copper from the tongue box. Decisions decisions.

Still needs a couple of coats of varnish, some cable management and cabinet tops and more than a couple other finishing touches but here it is......

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[Diemjoe]

I finally have the inside cabinetry done. Figuring out the lighting design took a long time and several attempts to get it to work. The cabinetry is about 80% from downed maple we got from a local arborist. It has been drying in my garage for the past 5 years. Still a bit warpy when I cut it up, resulting in not quite straight lines. But was fun to work with and finally put it to use.

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The lights are a cheap LED system from IKEA. The panel itself is attached by cabinet door clips at each corner. I doubt they'll hold through a bumpy road so I have to figure out something more secure but still presentable that will still allow me to remove it to access the lights and power cables if needed.

I got the glass from a lantern at goodwill. I also got some mirrors from goodwill. Cut them up and placed them a few inches behind the glass to diffuse the individual LED lights. I still have to seal out the light leaks around the edge though but I am happy with how it looks.

[S. Heisley]

Lookin' Good!

[Diemjoe]

Thought I was done with the electric but learned that the PD4045 isn't an inverter. When I go off of Shore power I lose the 120 outlets.
Since I don't have much that depends on 120, I think I am just going to remove the 120 converter from the inside LED lights, add a 12v USB charger plug and wire those back. Easier and cheaper than buying and installing an inverter and transfer switch.

I have a little cigarette lighter inverter that should do in a pinch.

[Diemjoe]

So Close..... But now so far.

I was thinking that I was just down to some finish work and registration but then I installed the galley hatch door latch. I noticed that the bottom of the door was sticking out about an inch while the top was tight against the wall lips.
based on some discussions with other builders here, I think that the plywood ribs have expanded/ tried to straighten out.

So I have to rebuild the door.

I just wish there was a way to figure out what when wrong with existing door so I don't have the problem again.

The top is perfect

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The bottom stick out a lot

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