I've been working toward the trailer inspection, which means I need this to have working trailer light and be able to travel on highway. I will probably don't have time to for aluminum skin installed, but I do want to apply the epoxy so that if rains, I am somewhat protected.
Things I will be concentrating are Hatch, doors, tongue box hatch and trailer lights.
First the easy stuff. Trailer side markers. I already had the main wiring done sometime ago, so only thing to do were to locate and mount. Front amber light and rear red light. Total of 4 lights.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-13220004_zps016a18f8.jpg)
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-13215954_zps74f7b3dc.jpg)
Next is the door.
There will be a door stop attached to the inside to hold the door when it is closed. And that's where I will be attaching door seal. To make them, I first needed to make a rough frame with 1x lumber.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-07214357_zps823ec5eb.jpg)
Then, using the layout I created, rough cut to the shape. Fat area at top right corner is where the switches will be mounted for the dome and porch lights.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-08215139_zps53200804.jpg)
I made a MDF template to route them to the same shape. After that, sanding, sanding and I am still sanding...
It will looks light something like this when mounted.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-17131224_zps7d73f714.jpg)
I should have made the lip a little wider. There won't be much of overlap with door to seal...
This is where the switches will be mounted. I need to make the hole deeper to mount the switch I ordered. The switches will be mounted on a aluminum plate, and that will be mounted over the hole.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-17131312_zps883e51a2.jpg)
Now that I got the door opening in a decent shape, I started to work on the actual door.
Using the cutout from the wall, spaced out evenly in the opening and attached the hinge to hold it in place. Cut out a hole for the window as well.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-18170955_zps15b0a78f.jpg)
This window is a crank-out type, I wanted it for the ventilation. I will be mounting it as low as possible. I still be able to look out sitting from inside, too.
![Thumbs Up :thumbsup:](./images/smilies/econ_thumbsup.gif)
One thing I noticed is that I don't think I left enough space between top hing and the corner of window for window drip cap. I will have to check that when I get it.
I also mocked up the door latch.
This latch is design for door/wall thickness of 1-1/4" to 1-1/2". My wall is 2 layers of 1/4" with 3/4" plywood core, but each thickness is not exactly that dimension.These 3 layers of plywood are less than 1-1/4" and needed to add another 1/4".
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-15210712_zps3761cd78.jpg)
I had to remove the deadbolt mechanism to slide it in.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-15210917_zps484d0355.jpg)
I need to make another mock up with extra 1/8" instead of 1/4". I don't want the thickness of wall and door to be different too much.
Last progress is on the hatch.
I skin the hatch with 1/8" baltic birch and mounted tail lights. License holder is taped on there for now.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-18160324_zps6d6456c6.jpg)
I had to make the galley wall off set for the hinge and seal, and I have been dreading this. But I could not wait any longer. I just had to do it.
I first made a template from 1/4" plywood so I can use on both side. I traced the offset distance from the inside of the hatch.
This is template mounted on the wall ready to be routed.
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-17170839_zpse85b5449.jpg)
And this is after. I think the gap is about the same all the way.
![Smile :)](./images/smilies/econ_smile.gif)
![Image](http://i1025.photobucket.com/albums/y317/Ryu_Fukami/2014-05-18160227_zps3af89bb4.jpg)
I repeated the same process on the other side.
I hope to have the trailer inspected by middle of June.
![Twisted Evil :twisted:](./images/smilies/econ_twistedevil.gif)