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    I’ve been doing other things for a while… but I’m back, baby! Prepare for many more photos…

    At first I mounted the axel as instructed, but that made everything waaay too tall with the 12″ wheel option. So we ended up flipping the trailer over and re-mounting the axel inside the leaf springs instead of outside (same as Waterlust did).

    Got both doors mounted. I found that some foam-core board made an ideal spacer for getting the doors clamped down for hinge alignment. Then I went out and found some screw posts that happened to fit perfectly in my hinges once I added some nylon washers. Having replaceable bearing surfaces will be a good thing later, I’m guessing. I’ll try to find mylar or teflon washers and nice brass screw posts later. In the meantime, this hardware store junk should work great!

    Next, it’s on to the galley hatch. I’ll also be adding nylon washers there. I’ve got a little file-work to do because that makes the hinges wider than the existing holes. To get things lined up, I stuffed the galley with pillows and stuff then squished the hatch down on top. I think this will work great!

    I’m a little concerned about the width of the galley side-walls. I think I deformed them a bit in a previous clamping and filleting step. Now the opening is a little bit wider than the width of the actual hatch… oops. We’ll see how things look later this week after I finish the hinges.



    I’m digging the hinges. Nice work! I had wanted to do something similar but couldn’t make it work. As well, good idea with putting a spacer on the doors when aligning them. I did something similar and it helped. Though my doors aren’t perfect, I think it certainly could have been worse if I hadn’t put something to simulate the gap. It’s looking good.



    I’ve been thinking about the doors a bit. There’s got to be a better way to do those. The current construction method has you cutting them out and THEN installing the door stiffener and the door frame. This is almost guaranteed to result in the doors not being the same shape as the shell after you install the frame. I think if the door frame was built up in two parts, you could install it first (overlapping the cut line) to stabilize the shell AND the door. Then if you cut the door out by cutting down the middle of the frame, you would end up with some of the frame glued onto the door and some of it glued onto the shell. Hopefully they would both hold the same shape at that point. Then you could just glue on a lip to the shell part of the frame to act as a door stop/seal. Something to think about for next time. 😉

    Jumping over to a different task… I got the mounting holes marked and drilled from the bottom.

    Then I taped up the bottom and filled the holes with thickened epoxy. After that cured, I re-drilled from the top.

    My holes weren’t perfectly vertical, but it turned out ok because I didn’t get into the wood and there is enough slop designed in that everything still lines up well enough. The bolts are a bit loose in the holes.

    I’m super duper happy to have this step done. Just need to finish mounting the galley hatch and then I’ll be down to just finish work. Sanding, varnish, etc.

    • This reply was modified 2 weeks, 1 day ago by  Dan.


    This weekend I got the eyebrows and hatch-back hinges installed. The hinges have been giving me nightmares for weeks. Glad that’s finally over. The only thing really of note with those is that they need to be parallel to each other and that means that they won’t just sit flush with the top of the shell. I turned the teardrop to be in-line with the slope of my garage floor then used a level to get the hinges straight.

    I have some fit issues with the hatchback. It wants to contract inward like you can see in this next pic. I will be gluing a lip around the sides of the opening for the door to come to rest upon. If I don’t, there will always be a gap like this. In the meantime, I braced it up with some foam-core board so everything would be flexed into the correct shape for the hinge glue-up. A weight at the top of the hatch also helped to align the top edge.

    In the end, they came out great! Opening the hatch back is smooth as butter.

    Next up, eyebrows! The doors hit, because of course they did. A little careful eyebrow trimming (ha) and it’s no issue.

    I am a huge fan of pre-wetting the fiberglass tape. That technique works SO well! One more coat of epoxy on the eyebrows and exposed bits of wood such as hinges tonight then I can sand the entire mess tomorrow and be ready for varnish on Wednesday. Road-worthy by next weekend? Unlikely, but possible! I want to get this thing in service and worry about interior finishing as I’m using it.



    I used.mine for a year before installing my headliner. Left me able to make changes if needed.

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