Kind of like a Grumman

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Re: Kind of like a Grumman

Postby Dusty Mark » Tue Jun 28, 2016 8:58 am

Cutting all those grooves in the foam seems like it takes forever, but it sure makes the foam bend easily...
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Re: Kind of like a Grumman

Postby ELM » Tue Jun 28, 2016 9:10 am

Dusty Mark wrote:Cutting all those grooves in the foam seems like it takes forever, but it sure makes the foam bend easily...

Cutting to grooves was way less time consuming than cleaning up the foam dust everywhere. But grooves do make it bend really nice. Today I'm going to sand the foam down flush to my framing. I will post pictures later today.
Last edited by ELM on Tue Jul 26, 2016 3:19 pm, edited 1 time in total.
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Re: Kind of like a Grumman

Postby Dusty Mark » Tue Jun 28, 2016 10:43 am

That's where I was thankful for my dust collection system connected to the table saw. It didn't get all of it, but almost all of it.
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Re: Kind of like a Grumman

Postby ELM » Tue Jun 28, 2016 2:10 pm

Dusty Mark wrote:That's where I was thankful for my dust collection system connected to the table saw. It didn't get all of it, but almost all of it.


I did hook my shop vac to my small table saw that I was using outside and it did catch most of it.
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Re: Kind of like a Grumman

Postby ELM » Tue Jun 28, 2016 3:11 pm

Here's a few pictures of the foam before and after sanding. The 1 1/2 foam that I bought was actually 1.587 so it needed to be sanded. I made a long sanding board or in my case a piece of 1"x1" steel tubing with a piece of 40 grit sand paper glued to it.
This a picture of the left side before sanding Image
And this a picture of the left side with some of the sanding done.
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And the left side done.
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This is the front before sanding
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And the front after sanding
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And the right side before sanding
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Right side after sanding
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And the top sanded
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I'm glad that job is done. :D :beer:
Next I get to start putting on the 1/4" Baltic Birch for the walls and 1/8" for top. :)
Last edited by ELM on Fri Jul 01, 2016 2:59 pm, edited 1 time in total.
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Re: Kind of like a Grumman

Postby ELM » Fri Jul 01, 2016 9:37 am

Here's a picture of the right side 1/4" Baltic birch installed. I think I used 33 different clamps.
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I let the right side glue dry overnight and installed the left side the next day.
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And the left side galley wall.
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Re: Kind of like a Grumman

Postby ELM » Fri Jul 01, 2016 2:55 pm

Here's a picture of the right side unclamped and trimmed.
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Here's a picture of the front with Birch glued and trimmed.
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And a picture of the right front birch glued and trimmed.
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And here's a picture of the top glued and trimmed.
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That's a good job done. :applause:
Next up is skinning the outside of the hatch and running the wires for lights. I'm also going to install the window and door for a test fit.
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Re: Kind of like a Grumman

Postby KCStudly » Fri Jul 01, 2016 6:44 pm

Looking great! :thumbsup:
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Re: Kind of like a Grumman

Postby ELM » Fri Jul 01, 2016 8:24 pm

KCStudly wrote:Looking great! :thumbsup:


Thanks KC
I just glued ( Loctite Premium) the birch plywood on the outer hatch frame. :) I think I might add some 6/32 brass screws to the outer frame also. :thinking:
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Re: Kind of like a Grumman

Postby plectrudis » Sun Jul 03, 2016 2:39 am

Gosh, it looks handsome, ELM!

That sanding job on the insulation must have been a major pain the arse. But I'm sure it's worth it to have such a tight, trim, clean fit.
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Re: Kind of like a Grumman

Postby ELM » Sun Jul 03, 2016 9:36 am

plectrudis wrote:Gosh, it looks handsome, ELM!

That sanding job on the insulation must have been a major pain the arse. But I'm sure it's worth it to have such a tight, trim, clean fit.


I'm glad I sanded the foam. It was well worth the time in the end, But a big mess.
All the joints came out nice and tight along the roof line :D I can see the end in sight. Thanks
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Re: Kind of like a Grumman

Postby ELM » Sun Jul 03, 2016 2:00 pm

Got the outer hatch Baltic birch trimmed and the hatch back on.
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A view from the front looking back at the hatch.
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And a view from the right corner of hatch. I'm happy :D with the way it fits.
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I installed the tail lights, license plate light and an old plate for hole placement.
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I want to put a third brake light up high on the hatch but I can't find one with a angled bezel so it points back and not up in the air. :thinking:
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Re: Kind of like a Grumman

Postby cubbyboy57 » Sun Jul 03, 2016 7:42 pm

WOW! Looks great ELM, she is going to be a beauty.
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Re: Kind of like a Grumman

Postby ELM » Sun Jul 03, 2016 11:56 pm

cubbyboy57 wrote:WOW! Looks great ELM, she is going to be a beauty.


Thanks.
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Re: Kind of like a Grumman

Postby ELM » Sat Jul 16, 2016 8:36 pm

I've been working the teardrop but just a bunch of little things. I've also been working on the wiring on the under side of hatch like the three Galley lights, tail lights and license plate light. Here's a picture of the foam installed and sanded.
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Here's picture of the Baltic Burch glued and clamped. I needed one clamp :lol: :lol:
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