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Assembly instructions for the SUT-1000-CLC are available, gratis, in .pdf format, from trailex.com. Click on “Resources”, then the model number. No dimensions, but the photos may be helpful in your design work, as well as interpreting the dimensions below:
- Frame extrusions are 1.25″ x 4″
- Tongue extrusion is 2.5″ x 4″
- Triangle is 30.75″ high from front surface of front cross member to forward edge of end of triangle side piece (nearest the tongue). The triangle base is the same width (58.5″) as the width of the “square” (rectangle, actually)
- The tongue is 44.5″ from the forward edge of end of triangle side piece to the front tip of the coupler
- The side pieces are 68″ long, outside surfaces 58.5″ apart
- The cross members are 21.5″ apart, center to center. The front surface of the front cross member is 2″ to the rear of the front of the side pieces
P.S. I used marine grade, heat shrink, adhesive lined, crimp connectors on all wiring harness connections. For the side marker lights, I skipped the corrosion prone Scotchlock connectors and ran 18 gauge (marine grade) primary wire from the side marker lights to the rear of the side rails, connecting the other two running light wires (harness and taillight) using heat shrink, adhesive lined, cap crimp connectors. Black plastic, 1″ square tubing caps neatly finished the two square openings at the rear of each side rail, and kept the wiring harness securely inside.
A Bosch RO520VS (now RO520VSC), $70 or so in the big box stores, has served well on my build. It came with (and the “-C” model does also, per the Bosch website) a “VAC002” adapter, which connects perfectly with the hose end on my purchased-for-the-project Vacmaster 4 gallon shop vac. It’s quieter than the sander, so not a howling monster, but it keeps the disc and surface being sanded clear of sanding debris. It has a HEPA filter on the exhaust, which helps reduce the amount of dust that gets into the shop air. I bought a spare hose so I could zip tie the sander cord to one and leave it semi-permanently attached, leaving a hose available for vacuuming jobs. Don’t waste money on the crummy sanding discs sold at the big box stores; Indasa Red Line Rhynogrip discs are available online in the 8 hole pattern that matches the Bosch pad. The slight premium in price (around $22/box vs. $15) is more than offset by the much longer useful life (and time saved in not having to change a disc after sanding a square foot of okoume or epoxy). I have had good service from a distributor in the Northeast that has a flat shipping charge of $5 for orders over $50, free shipping for orders over $200.
“Assembling and Installing the Cabin Shelf” begins on page 229 of the manual. “Assembling and Fitting Door Sills” begins on page 224. The bottom photo on page 226 clearly shows the cabin shelf, already installed. On pages 232 and 233 the respective top photos clearly show the raw door opening in the camper shell as Dylan diligently tacks and fillets the shelf.
I installed the cabin shelf prior to fitting the door sills, following the order of operations in the photos rather than the text; shelf installed (without any alterations/trimming), the door sills went in just fine. If you’re a little particular (like me), prior to filleting, jigging the shelf in place with 6″ clamping squares and a couple deep reach clamps from horror fright assure the shelf will be reasonably square to the bulkhead.
re: bubbles forming with temperature increase – Charles’ Law states that a gas expands as its temperature increases. Air in the plywood outgasses as the temperature increases, forming bubbles in the overlying, uncured epoxy. So, applying epoxy as temperatures are decreasing will mitigate bubble formation. I’m pretty sure this is randomly mentioned somewhere in the hymnal, but can’t find the page at the moment.
Amazon: Wooster Brush R730-9 Tiz Foam Roller Cover, 1/8-Inch Nap, 2-Pack, 9-Inch $5.05 per pack.
Home Depot: 2″ capacity spring clamps 99 cents each. Cheap and good; pick through the box to get decent jaw alignment and even spring tension.
Harbor Freight: Boxes of 3 dozen chip brushes for less than a dozen would cost anywhere else (even cheaper if you use a 20% off coupon from one of their ads in home fix-it, car, weekly throw-away, etc., magazines). Also nitrile gloves in sizes (better fit than “one size fits most” exam gloves).
