5' X 10' Grumman 2 Sort Of

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Re: 5' X 10' Grumman 2 Sort Of

Postby KCStudly » Fri Apr 08, 2016 9:54 am

Many use a cheap sheet of 1/4 underlay or luan to make a master template of their whole profile. All details are draw and/or cut on the template first, both to check for oopsies and to have a permanent record of locations. They make a good router template, too.
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Re: 5' X 10' Grumman 2 Sort Of Day 21

Postby RunnerDuck » Wed Apr 13, 2016 7:54 pm

This is actually three days rolled into one.

I've been working really hard and making good progress. I've got the inner plywood walls trimmed to my pattern and the outer plywood walls trimmed to the pattern.

I've got the outside aluminum siding on order and I will pick it up Monday.

Here are a few photos of the last few days.

This is trimming the plywood with a router trim bit.
route wal 2.jpg
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Trimming out the door opening.
Route Wall 1.jpg
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And finally a fit test of the walls! This is a big milestone and I'm really excited with how well they fit :D
Wall Test.jpg
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Things are really starting to come together. It's really something to see it actually starting to look like my drawings. I still have a long way to go but at last some really visible progress!
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Re: 5' X 10' Grumman 2 Sort Of

Postby KCStudly » Wed Apr 13, 2016 8:28 pm

:thumbsup:
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My Build: The Poet Creek Express Hybrid Foamie

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Re: 5' X 10' Grumman 2 Sort Of Day 22

Postby RunnerDuck » Sun Apr 17, 2016 9:30 am

It's been a couple more days and I've been working on the roof trusses. I've got the roof trusses all glued up. They are 1 1/2" X 1 1/2" made up of 3/4" thick mahogany.

I'm just glad that I've got lots of clamps!

trusses.jpg
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I cut down the piece I trimmed from the top of the core to make truss spacers.

truss spacer 2.jpg
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Here's a shot of the truss spacers and trusses being test fit. I think they are going to work great! They will go on top of the 1/8" plywood ceiling.

trusses 2.jpg
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It's great to be showing lots of progress. I just may have myself a teardrop someday :wine:
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Re: 5' X 10' Grumman 2 Sort Of

Postby guymi » Sun Apr 17, 2016 9:40 am

:thumbsup: Superbe :applause:
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Re: 5' X 10' Grumman 2 Sort Of

Postby ELM » Sun Apr 17, 2016 9:50 am

Looking nice. :)
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Re: 5' X 10' Grumman 2 Sort Of

Postby Vedette » Sun Apr 17, 2016 2:07 pm

Hope it is ready for the Farm Gathering :thinking: .....We have a "Show 'n' Brag" for you to show off your achievements! ;)
July 14 - 17th.
Your progress looks great, don't let up.
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Re: 5' X 10' Grumman 2 Sort Of

Postby RunnerDuck » Sun Apr 17, 2016 4:19 pm

Only time and a lot of work will tell.

Don't count me out just yet :NC
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Re: 5' X 10' Grumman 2 Sort Of Day 23

Postby RunnerDuck » Wed Apr 20, 2016 9:07 am

Day 23 consists of two days. The first day I dove off island to pick up the Dibond that I'll use for the outside wall covering. Then I picked up four sheets of 1/2" Baltic Birch plywood for the inner wall and some of the cabinet structure.

The next day I rough cut one of the sheets of Dibond with my scroll saw. It took a few tries with different blades to find one that cut fairly smooth. I traced around the pattern with a Sharpie and then moved it aside to make my cuts.
Cutting.jpg
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Once I had the rough cut done I put the pattern back in place and routed around it with a flush cut router bit. What a mess it made. The cut was perfect buy my shop was a mess. The black plastic inner core of the Dibond just came off in tiny pieces you can see on the plywood and floor.
Route.jpg
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As soon as I get the second side cut out I should be ready to start laminating up the walls. It sure is getting exciting now :D

Stay tuned!
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Re: 5' X 10' Grumman 2 Sort Of Day 24

Postby RunnerDuck » Sat Apr 23, 2016 11:22 am

I finally started putting the walls together. I started with the inside skin first. I spread PL glue all over the core with a notched trowel and then put it on the birch plywood.

Since I drink a lot of milk and saved up a bunch of milk cartons that I use as weight clamps. I do believe they will do the trick.
wall skin.jpg
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The adhesive has a 24 hour clamp time so won't know until I check it out this morning.

I think I'll add the rigid insulating foam next.

Stay tuned!
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Re: 5' X 10' Grumman 2 Sort Of

Postby ELM » Sat Apr 23, 2016 2:11 pm

Good idea there. I use steel for weight since I have a lot around. I can hear my Dad saying. That's the way to use your head for something other than a hat rack. Your moving right along there and it's looking good. :)
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Re: 5' X 10' Grumman 2 Sort Of Day 25

Postby RunnerDuck » Sun Apr 24, 2016 9:00 am

Thanks for the compliment ELM. I just don't have much heavy stuff around so seemed like the best I could come up with.

I couldn't use empty wine boxes but it's really difficult to refill the empty bags inside. :wine:

Today I glued in the rigid foam insulation and I think it turned out great.
Insulation.jpg
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I cut groves in the foam to run my electrical wires to my light switches and tail lights. I laid in some heavy string and tied a labeled washer to each end. That will identify each string and prevent it from pulling back through any holes. Hopes are high that it will work as planned.

Next up, glue the outer plywood on and then glue the outside "Dibond" skin on.

I'm getting pretty excited to get the first wall done.
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Re: 5' X 10' Grumman 2 Sort Of

Postby KCStudly » Sun Apr 24, 2016 9:51 am

If your wire pulls are dead straight the string trick should work okay. However, if you have any turns or corners and are pulling anything more than just a couple of wires with minimum resistance, the string can cut into the foam and cause a bind. First hand experience here. It will go eventually, but you may sacrifice some insulating value and your wires may take some shortcuts.
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My Build: The Poet Creek Express Hybrid Foamie

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Re: 5' X 10' Grumman 2 Sort Of

Postby RunnerDuck » Sun Apr 24, 2016 11:59 am

Thanks KC for the comments. One thing I always respect is "experience", especially "bad experiences"!

I've made every effort to keep the groves fairly straight. There is one with a little curve I'm a tad worried about but I think if I'm easy with it, it should work.

My other option is to run the wire with the little curve now and just have a coil of wire to deal with at one end, then there would be no binding. I'm still thinking :thinking:

Thanks again!
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Re: 5' X 10' Grumman 2 Sort Of

Postby ELM » Sun Apr 24, 2016 2:11 pm

I've used poly flow tubing for wire conduit when I need to run wires through and in my steel tubing. My be it would work in your foam also.
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