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I would estimate 200 hours to build mine with box (Battery and storage up front)
I didn’t track details but I found it hard to work more than a couple hours unless you were doing a big fiberglass section or big epoxy work.
I could flip it in single garage so not much outside help was needed. I am sure I could have sanded more too.
Good Luck with your project.
I also had a few Beer sessions while reading instructions with no actual work but working thru the thought process to next steps…
Got Pictures? That would be helpful.
Where are you located?
The gasketing from CLC is pretty amazing, just need rubber mallet to install it..
I have only travelled about 500 miles. I chose not to fasten my galley for a couple reasons, primarily “rub wear” you describe but also for ease of cleaning. I place it insde the terdrop where rides comfortably. Only 1 wire to connect for USB Plug. Battery is mounted in CLC Storage box up front. Cheers!
How much are you asking? More pix?
Might be best to start with the Storage Box. Smaller amounts of Fiberglass and Epoxy too. Errors can be sanded out and redone. From experience, I can tell you the covering of the shell is a big task so a little practice would be helpful.
I am not aware of warping in sun but they do take a different shape when held open for long periods of time. It is slight but noticable when you first close it. Keep it closed when not in use.
MAke sure your stiffener does not impede your Galley. When all done’ it makes a snug fit between Galley and Hatch. Best of luck and enjoy the build.
My Advice.. take your time, enjoy the building process as this very cool Teardrop comes together. It is not a race to finish, or shouldn’t be a race. This is a process that takes time and consideration and a ton of sanding. Do not skip any steps, do not rush your epoxy or Varnish. I did not track my time but I am sure building almost completely solo was about 200 hours. I even flipped the teardrop a few times by myself…
Set up your workspace with some music, chairs, beer fridge… you get the picture.
The result will be amazing and if you drive to finish quickly you will miss the beauty of the process.
Cheers and Good Luck!
I am in Arlington TX so not too close. Built all of mine except insulation which I have but not installed.
Email me or call if you need some support firstname.lastname@example.org
I did 5 thin coats with Water Based Varnish. Could do more but looks quite nice. Sanding will make you crazy if you lack patience. Good Luck
Looks ike this worked well. I would have considered adding 2 more latches to simplify. Well done 🙂
When the package arrives, I would recommend keeping as much of the Packaging to use as “drop cloth” for all you do.
Sit down with your Builders Manual and read it completely. Your first project is to build the Exterior Frame. Be accurate as you will use this to form the rounded shell. Align all your panels well, stitch carefully, initially snug but then when ready, tighten all stitches. The CA glue makes this process super simple. Keep in touch as I took about 12 months of nights and some weekends to complete mine. A solid stash of cold beer and good music source are also very helpful… and patience. Good Luck. Where are you located?
For interior lights I also wen as close to ceiling as possible. My drilled holes were so small I had to force the wire thru. FYI, I used a Black fabric covered wire (very old school look) that I found on Amazon. No grommets.
Be sure you match up your Electrical Panel with the Galley framing. I used a much lower cost Panel and had a slight interference issue. Probably because I never considered it could have an interference.
The way the Galley fits, it hides the back of your Panel pretty well. (Now if I can just resolve my Mushroom Vent leaks and Galley leaks… )
Merry Christmas and a Happy 2019!
Take extra care when “filleting” as sanding in that tight space is a challenge. And this is quite visible once finished. Good Luck!