Hi Jst83/Scot,
Since you seem to be planning a little reworking this winter before
you canvas the TD body, I have a suggestion for your edges where you
need a water/dust seal...
I don't know if this will work or not, but why not look into some of the
PVC "boards" they sell for exterior house trim ? I don't have personal
experience with it - just from what I've seen on DIY TV shows etc. -
but I understand it comes in dimensions compatible with the usual wood
nominal sizes and sheet good dimensions. They can be worked with normal
woodworking tools from what I understand.
Here is a link to the first manufacturer that came up on a Google search:
http://www.certainteed.com/products/trim/trimboardsPlus another manufacturer's web site:
http://www.azek.com/azek-trim/http://www.azek.com/azek-adhesive/http://www.azek.com/azek-to-mill-atmThey are made from a PVC foam and edges are sealed etc. Some is even
'millable'. It looks like there are multiple edge designs - "Js", flanges etc. -
that could be used to your advantage as pre-made rabbet edges for the
areas that you need to apply seals to and the edges to close against those
weather seals - like a face frame with rabbeted overlapping edges on the doors.
I'd assume that you could glue them to the existing PVC frame openings
you have, or maybe insert new frame openings into the existing PVC
body framework. One possible method would be to rip the PVC board
to 1 or 1&1/2 inches and use a coving bit in a router to cove the edge that
would be placed against the round PVC framing sections - this would give
a much stronger gluing surface connection. That'd give you square edges around
the hatch and door and window openings, that would then allow you to use
corresponding squared door, window and hatch edges which would allow
you to apply weather-stripping and achieve a good seal.
You'd just have to experiment a little to see if it would work, but I really can't
see any reason why it would not. Also, I don't know the structural strengths
of these boards, but your method of inserting galvanized conduit inside the round
PVC framing members [do so in the round PVC around the openings] should also
thus reinforce the relatively small section square edges that you'd be gluing to
the round PVC members. I also don't know the cost, I assume it may have a more
premium price, but you won't really need a large amount to accomplish your needs.
It'd probably be a case of the "right" material to use for your needs and save you time
and effort as well.
Just an idea that may work for your situation and needs with the "DDG -
the DuckDuckGoose" build.
Cheers,
Norm/mezmo
If you have a house - you have a hobby.