This topic contains 5 replies, has 4 voices, and was last updated by  western_flyer 2 months ago.

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  • #1833

    madnav87
    Participant

    Has anyone else had difficulty fitting the cabin shelf into place after installing the door sills? It appears that there is no way for it to fit, given the shape of the shell. Do I just need to be a bit more persistent trying different orientations, or is the solution to trim the corners off the shelf?

    #1835

    Dan
    Participant

    @artisticadam mentioned that he figured that out here. Maybe he can share his video with you.

    #1840

    ArtisticAdam
    Participant

    Below is the video in question for installing the shelf. Just make sure you round off the back corners of the shelf to accommodate the fillet between the bulkhead and camper shell. The 4 holes that the shelf slot into also needed some cleanup from epoxy drips. I opted not to install the fiddle rail so hopefully this process works for those with the rail. No additional sanding on the shelf was required for me to fit it in place.

    https://www.dropbox.com/s/w8z3zm4yd8h1hw0/VID_20180328_212408356.mp4?dl=0

    #1843

    madnav87
    Participant

    Thanks @artisticadam! Actually, as it turned out, the rail was the part that was hitting the door sills. So, I wound up having to trim the edge of the shelf. I simply routed/sanded it to seem as if I meant to do it that way!
    By the way, I like the stain on your camper. I considered doing something similar, but was hesitant because I thought any scratches or blemishes in the plywood would stand out. However, once the epoxy resin gets into these scratches, they stand out any way! Here’s a shot of the build thus far ,after about 10 days of pretty constant work. I won’t be able to finish it (had to move for work), but the goal is for my fiancé to finish it in the next month, in time for us to take the teardrop on our honeymoon! Fingers crossed that the conditions will be good for varnishing later this month (unlikely, given the location….Florida). 

     

    • This reply was modified 2 months ago by  madnav87.
    #1845

    western_flyer
    Participant

    I ran into the same problem installing the bulkhead shelf.  I gave it a trial fit after installing the bulkhead. It was a very tight fit and it looked like it would interfere with the door framing so I held off on the shelf until after the framing was glued in place.  Of course there was no getting the shelf in place without risking damage to the TD skin once the framing was in. I wound up shaving 3 or 4 mm off each end of the shelf. This left a pretty large gap between the shelf and skin to bridge with an unsupported fillet. I thought about adding some fiberglass tape but just put an extra fat fillet where the shelf meets the door frame. It looks solid but I will keep an eye on it when I get on the road.  IMO the manual needs to be corrected to showing the shelf either tacked or filleted in place before the door frames are installed.

    #1846

    western_flyer
    Participant

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