Welcome to the "Learning Curve"

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

Re: Welcome to the "Learning Curve"

Postby Lou.Catozzi » Tue Nov 07, 2017 10:16 pm

I really like that shape. Well done thus far!


Thanks Johnysteam! Slow and unsteady, that's my progress report. That Semi-Standi of yours is pretty sweet. You have the interior decked out pretty nice. I hope mine finishes out as nice as yours!
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Lou.Catozzi
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Learning Curve - Build Days 18 & 19

Postby Lou.Catozzi » Mon Dec 11, 2017 6:42 pm

Well, things are progressing slowly. Over the past month or so I've been working on the starboard wall framing. I have most of the framing in place forward of the galley bulkhead. I'm still working out the details of the hatch to sides joint so I wanted to get at least one wall vertical and temporarily in place so I could visualize things better.

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This is a wide angle photo so some of the framing looks skewed. It really isn't. Everything is nice and plumb and level that should be. Rather than finish the wall framing aft of the bulkhead I have gone ahead and started framing the port wall. After that piece has caught up to it's twin I'll continue designing and building out the wall design before starting on the galley area and the cabin interior cabinetry. I've also started planning out the electrical systems. At this point I think I'll go with a 12V deep cycle battery on the tongue and charged from the Jeep to power all the lighting and a few USB charging ports and a separate 120V system to power a few outlets in the cabin and galley from shore power at established campgrounds. I plan to use propane canisters for cooking and possibly for lighting in the galley while boondocking. No solar and no battery charging from shore power at this point.
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Lou.Catozzi
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Learning Curve - Build Days 18 & 19 - Continued

Postby Lou.Catozzi » Sat Jan 20, 2018 6:11 pm

Today wasn't really a build day. The only tools I used was a ruler and a pencil. This was the first day in about a month that the weather and my health allowed me to even play with the project. I rolled it outside into the driveway and stood up the port side wall and temporarily braced it to get a give me an idea of the size of the finished project.

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It is bigger than I have been imagining for the past two years of looking at drawings. It is going to be interesting to see how the Jeep behaves when I try to go somewhere with the teardrop in tow.

Next steps are to finish routing the walls in preparation for adding the roof, finishing the galley design, and then start running the wires in the side walls. After that I'll insulate the side walls, put on the inner wall skins, and get them permanently attached to the floor.
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Lou.Catozzi
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Learning Curve - Build Day 20

Postby Lou.Catozzi » Mon Mar 12, 2018 8:31 pm

It's been a while but today the stars aligned (weather, health, time, money) enough for me to spend the day working on the teardrop again. I glued in two layers of 3/4" foam panels into the port wall framing and ran most of the wiring for that side of the trailer.

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After that I decided to cut down the wall template from it's exterior wall skin profile to that of the cabin interior. That involved cutting about 5.5" off the bottom edge of the template, cutting off the aft end of template at the interior edge of the bulkhead, and trimming the roof curve down 1.625" which is the thickness of the headliner and roof foam and fiberglass.

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The interior wall template is just laying on top of the port wall to help visualize the interior wall at this point. Ignore that extra hole to the left of the one with the wires! Measure once, drill twice, not!

Next up will be finishing the port wall wiring, cutting the interior wall out of 1/8" birch ply, and routing out the ledge at the top of the wall for the roof system to rest into. Then on to the starboard wall. Forward!
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Lou.Catozzi
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Learning Curve - Build Day 21

Postby Lou.Catozzi » Sat Mar 17, 2018 7:20 pm

Today I made some great progress.

First I finished running the wiring in the port wall. My fuse block and ground buss bar will be in a cabinet in forward end of the cabin. When I cut the foam for each wall cavity I left an inch open at the bottom of the wall and drilled holes thru each wall stud as a place for the wiring bundle to run. Wires go from the floor up inside the the wall just aft of the door frame (for the cabin and porch lighting and for the roof vent fan) and just forward of the aft bulkhead (turn/brake/licence plate on galley hatch and power for galley lighting).

Next I sanded down the foam insulation in the wall cavities. The walls have 1.5" framing and there are two layers of 3/4" rigid XPS foam. Unfortunately, the XPS is actually .8" thick so I have to sand it down level with the framing before I can apply the interior wall skin.

One of the reasons that I haven't made a whole lot of progress lately is that I was up against a task that I hadn't figured out how to do with the tools and materials I had available. When that happens (often!) I usually respond by slowing down progress on the tasks leading up to the puzzling task until a solution appears or occurs to me. Today I think I have solved one of those types of tasks that have been bugging me. The wall framing at the top of the wall where the roof attaches is made up of shaped pieces of 1.5 x 3" poplar on edge vertically and smoothed to the curve of the roofline.

I need to cut a ledge out of the inner surface of this poplar so that the headliner and the foam sheets that make up the roof can sit flush with the outside top of the walls.

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Today I finally came up with a plan to carve that ledge. My template for the inner wall skin and the inner edge of the ledge is less than 1/4" thick and the ledge needs to be 3/4" deep. The Perfect tool for the job would be a straight router bit with 3/4" cutting length and a bearing to ride on the edge of the template. However my only similar router bit has a 1" cutting length. That would cut too deep by itself. My solution (a really simple one after I finally thought of it) is to make a thicker template with a piece of 1/2" BB plywood I had left over. BB plywood is not cheap but it is cheaper than a new router bit IF I could even find one with a 3/4" cutting length (depth?)

That was my day. Next up is to try this solution by cutting the ledge on the port wall.
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Lou.Catozzi
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Re: Welcome to the "Learning Curve"

Postby clamlamp » Sun Apr 08, 2018 4:15 pm

great job so far on the build! :applause:
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