. slides/maiden_voyage.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Here is the finished tear sitting proudly in the Sierra's on her maiden voyage. At 740lbs. it pulled so smooth and easy with no bounce that I had to keep checking the mirror to make sure it was still following and went straight arrow through heavy desert wind gusts. Keep clicking the center photo to watch it being built. Here is the finished tear sitting proudly in the Sierra's on her maiden voyage. At 740lbs. it pulled so smooth and easy with no bounce that I had to keep checking the mirror to make sure it was still following and went straight arrow through heavy desert wind gusts. Keep clicking the center photo to watch it being built. slides/maiden_voyage.jpg slides/axle.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 September 23rd 2003 - This was where it starts. The axle and suspension finally arrived from R.W. Johnson. It's a 4" drop with 1-1/2" springs on 39" centers. The hubs are 5 on 4-1/2" which is Ford's pattern. September 23rd 2003 - This was where it starts. The axle and suspension finally arrived from R.W. Johnson. It's a 4" drop with 1-1/2" springs on 39" centers. The hubs are 5 on 4-1/2" which is Ford's pattern. slides/axle.jpg slides/frame01.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 September 30th 2003 - I chose channel over square tubing for several reasons. There is no place for moisture/water to settle and with tubing there is no way to seal the inside. Might be one of the reasons that almost all boat trailers are made from channel. In any event it's just a matter of preference and channel will be very strong in this application. Here the two inch channel is cut to length and is being clamped and squared up prior to welding. I clamped quarter inch steel plates at joints to line up rails prior to welding. September 30th 2003 - I chose channel over square tubing for several reasons. There is no place for moisture/water to settle and with tubing there is no way to seal the inside. Might be one of the reasons that almost all boat trailers are made from channel. In any event it's just a matter of preference and channel will be very strong in this application. Here the two inch channel is cut to length and is being clamped and squared up prior to welding. I clamped quarter inch steel plates at joints to line up rails prior to welding. slides/frame01.jpg slides/frame02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 September 30th 2003 - A 25 degree notch was cut at the places on the outside rails where it will be bent to form the tongue. A 50 degree coupling will then be welded on that will also accomodate the tongue jack. September 30th 2003 - A 25 degree notch was cut at the places on the outside rails where it will be bent to form the tongue. A 50 degree coupling will then be welded on that will also accomodate the tongue jack. slides/frame02.jpg slides/frame03.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 2nd 2003 - After welding all but the front cross members the rails were bent to form a vee and then the front cross member was cut and welded in place. October 2nd 2003 - After welding all but the front cross members the rails were bent to form a vee and then the front cross member was cut and welded in place. slides/frame03.jpg slides/frame04.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 2nd 2003 - The rails were welded together where the notches had been cut out for bending the tongue. Also after squaring the frame a few gussets were installed to keep things from racking. October 2nd 2003 - The rails were welded together where the notches had been cut out for bending the tongue. Also after squaring the frame a few gussets were installed to keep things from racking. slides/frame04.jpg slides/frame05.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 2nd 2003 - 1/4 X 2" angles were welded on as a base to mount the spring hangers. October 2nd 2003 - 1/4 X 2" angles were welded on as a base to mount the spring hangers. slides/frame05.jpg slides/frame06.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 2nd 2003 - Six pieces of angle with 3/8" holes were welded in place as mounting brackets to attach the floor. Carriage bolts with fender washers will be used and two nuts locked together on the bottom. October 2nd 2003 - Six pieces of angle with 3/8" holes were welded in place as mounting brackets to attach the floor. Carriage bolts with fender washers will be used and two nuts locked together on the bottom. slides/frame06.jpg slides/frame07.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 3rd 2003 - Alright!!! Some hardware arrived from Champion trailer. October 3rd 2003 - Alright!!! Some hardware arrived from Champion trailer. slides/frame07.jpg slides/frame08.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 3rd 2003 - Frame completed with several coats of of paint. The exposed front part of the frame will be painted white as will be the connector. October 3rd 2003 - Frame completed with several coats of of paint. The exposed front part of the frame will be painted white as will be the connector. slides/frame08.jpg slides/frame09.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 3rd 2003 - Although torsion axles install easier and are a little less expensive I chose leafs. Both suspensions can break but the springs are available most everywhere, very easy to replace and you can limp into a town for parts. Torsion's are made to order and if one fails the tear is stranded for as long as it takes to make a new one - sometimes weeks. If towed it must be put on a flatbed which depending on mileage could exceed the cost of the original build. October 3rd 2003 - Although torsion axles install easier and are a little less expensive I chose leafs. Both suspensions can break but the springs are available most everywhere, very easy to replace and you can limp into a town for parts. Torsion's are made to order and if one fails the tear is stranded for as long as it takes to make a new one - sometimes weeks. If towed it must be put on a flatbed which depending on mileage could exceed the cost of the original build. slides/frame09.jpg slides/frame10.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 3rd 2003 - Trial fit to make sure the axle and suppension fit correctly. It's a 2000/lb 4" drop axle with 1000/lb springs on 39" centers. Note: This combination worked perfect with no bounce or sway in heavy cross winds. October 3rd 2003 - Trial fit to make sure the axle and suppension fit correctly. It's a 2000/lb 4" drop axle with 1000/lb springs on 39" centers. Note: This combination worked perfect with no bounce or sway in heavy cross winds. slides/frame10.jpg slides/frame11.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 5th 2003 - Underside of the connector is welded in place. The chains will also be welded to the frame. October 5th 2003 - Underside of the connector is welded in place. The chains will also be welded to the frame. slides/frame11.jpg slides/frame12.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 16th 2003 - Just trying an idea to mount some swivel casters up underneath in back to help me out of my steep driveway. Won't install unless needed on the first trip out the drive. Note: They were never needed. October 16th 2003 - Just trying an idea to mount some swivel casters up underneath in back to help me out of my steep driveway. Won't install unless needed on the first trip out the drive. Note: They were never needed. slides/frame12.jpg slides/frame13.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 16th 2003 - Some 5/16" flat steel was bent and scabbed onto the rails where the bends were made for extra strength. October 16th 2003 - Some 5/16" flat steel was bent and scabbed onto the rails where the bends were made for extra strength. slides/frame13.jpg slides/frame14.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 16th 2003 - OK . . . frame's finished so it's time to put away the welder and dust off the woodworking tools. The Toyota truck (same bolt pattern as Ford) wheels came from a wrecking yard with these old tires installed which will be replaced on completion. Note: when finished the tires were replaced with P205/R75-14's October 16th 2003 - OK . . . frame's finished so it's time to put away the welder and dust off the woodworking tools. The Toyota truck (same bolt pattern as Ford) wheels came from a wrecking yard with these old tires installed which will be replaced on completion. Note: when finished the tires were replaced with P205/R75-14's slides/frame14.jpg slides/floor2.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 23rd 2003 - Floor is 3/4" birch plywood with 1-5/8 X 2-1/4" frame rails glued and two inch screws every three inches. October 23rd 2003 - Floor is 3/4" birch plywood with 1-5/8 X 2-1/4" frame rails glued and two inch screws every three inches. slides/floor2.jpg slides/floor.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 23rd 2003 - Took lots of pains to get the floor and frame to size which makes the rest of the building go so much easier. The six carriage bolts mounting floor to frame have double nuts locked together which should stay tight. October 23rd 2003 - Took lots of pains to get the floor and frame to size which makes the rest of the building go so much easier. The six carriage bolts mounting floor to frame have double nuts locked together which should stay tight. slides/floor.jpg slides/underside1.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 14th 2003 - Several coats of marine spar varnish before bolting to frame. After priming the frame received three coats of gloss black Rust-O-Lium. November 14th 2003 - Several coats of marine spar varnish before bolting to frame. After priming the frame received three coats of gloss black Rust-O-Lium. slides/underside1.jpg slides/underside2.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 16th 2003 - After the floor was built it got three coats of marine spar varnish on the underside before bolting to chassis. November 16th 2003 - After the floor was built it got three coats of marine spar varnish on the underside before bolting to chassis. slides/underside2.jpg slides/sides.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 October 25th 2003 - Sides are 3/4" birch plywood. Made a quarter inch hard board template of the profile and then used a router with a 1/4" carbide bit and 7/16" collar to cut the shape. Made a couple passes on each side and they are virtual clones of one another. Note: The template was made 3/32" smaller than the finished wall size to account for half the difference between the collar & cutter size. Doors on each side of the cabin work great for two people and making the bed is much easier. October 25th 2003 - Sides are 3/4" birch plywood. Made a quarter inch hard board template of the profile and then used a router with a 1/4" carbide bit and 7/16" collar to cut the shape. Made a couple passes on each side and they are virtual clones of one another. Note: The template was made 3/32" smaller than the finished wall size to account for half the difference between the collar & cutter size. Doors on each side of the cabin work great for two people and making the bed is much easier. slides/sides.jpg slides/ribs.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 1st 2003 - Extra wood around where the vent will be so as to have some material to attach the vent with screws. November 1st 2003 - Extra wood around where the vent will be so as to have some material to attach the vent with screws. slides/ribs.jpg slides/ribs2.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 1st 2003 - Ribs are 1 X 2" clear poplar. This wood is very stable and strong. It also glues, holds screws well and is very resistant to dry rot and termite damage. They are held by two screws on each end and Tite-Bond cement. November 1st 2003 - Ribs are 1 X 2" clear poplar. This wood is very stable and strong. It also glues, holds screws well and is very resistant to dry rot and termite damage. They are held by two screws on each end and Tite-Bond cement. slides/ribs2.jpg slides/headliner.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 1st 2003 - Headliner is 1/8" birch and crossed my fingers when bending the radius. Addendum: On the next tear I will first glue the ribs to the headliner before and then install them as one unit which should make the bending easier and safer. November 1st 2003 - Headliner is 1/8" birch and crossed my fingers when bending the radius. Addendum: On the next tear I will first glue the ribs to the headliner before and then install them as one unit which should make the bending easier and safer. slides/headliner.jpg slides/wiring.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Wiring for remote vent with fan and halo light. November 3rd 2003 Wiring for remote vent with fan and halo light. November 3rd 2003 slides/wiring.jpg slides/wiring2.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Drilled small holes in the ribs for wiring and wrote down distances from the side so when installing the Masonite I could avoid shooting brads into the wires. Instead of notching, I drilled in the middle of the rib so as not to compromise it's strength. Drilled small holes in the ribs for wiring and wrote down distances from the side so when installing the Masonite I could avoid shooting brads into the wires. Instead of notching, I drilled in the middle of the rib so as not to compromise it's strength. slides/wiring2.jpg slides/insulation1.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 3rd 2003 - Just another view getting ready to install 1/8" top Masonite. November 3rd 2003 - Just another view getting ready to install 1/8" top Masonite. slides/insulation1.jpg slides/insulation2.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 2nd 2003 - I was able to put in three layers of half inch polystyrene insulation which bends easily. Addendum: After camping in 100 plus degree heat there was no heat buildup on the headliner. Don't omit the insulation which is only a few bucks per 4 X 8 sheet. November 2nd 2003 - I was able to put in three layers of half inch polystyrene insulation which bends easily. Addendum: After camping in 100 plus degree heat there was no heat buildup on the headliner. Don't omit the insulation which is only a few bucks per 4 X 8 sheet. slides/insulation2.jpg slides/hardboard1.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - These inexpensive straps were a great help since I did the complete build with no help. Hardboard is 1/8" tempered Masonite and follows the conture easily. The lines are just a reference to the center line of the ribs for driving brads. November 5th 2003 - These inexpensive straps were a great help since I did the complete build with no help. Hardboard is 1/8" tempered Masonite and follows the conture easily. The lines are just a reference to the center line of the ribs for driving brads. slides/hardboard1.jpg slides/hardboard2.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - The 2 X 3" oak hinge rib gives a sturdy place for attaching temporary clamps and will provide a strong member to attach the galley hinge later on. November 5th 2003 - The 2 X 3" oak hinge rib gives a sturdy place for attaching temporary clamps and will provide a strong member to attach the galley hinge later on. slides/hardboard2.jpg slides/hardboard3.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - Holding hard board in place while glueing. Also used lots of 3/4" brads then filled the holes. Chalk lines were snapped over ribs as a guide for shooting brads. Reminder - don't shoot brads into your electrical wires. November 5th 2003 - Holding hard board in place while glueing. Also used lots of 3/4" brads then filled the holes. Chalk lines were snapped over ribs as a guide for shooting brads. Reminder - don't shoot brads into your electrical wires. slides/hardboard3.jpg slides/hardboard4.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - The hinge rib is 2 X 3 oak with four 2-1/2" screws on each side. Rumor is this rib was the weakest part of the original Kit trailer but on this tear it should be one of the strongest. November 5th 2003 - The hinge rib is 2 X 3 oak with four 2-1/2" screws on each side. Rumor is this rib was the weakest part of the original Kit trailer but on this tear it should be one of the strongest. slides/hardboard4.jpg slides/hardboard5.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - Using straps to hold down hard board until adhesive cures. Of course another short piece will be added but the seam will be invisible once it is covered with the aluminum. November 5th 2003 - Using straps to hold down hard board until adhesive cures. Of course another short piece will be added but the seam will be invisible once it is covered with the aluminum. slides/hardboard5.jpg slides/breaktime.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - Just resting and doing some daydreaming of adventures to come. Long way to go yet. Rule #1: Have all your hardware on hand to avoid any unpleasant surprises. I learned my lesson with the galley hurricane hinge when the manufacturer changed the design to zero offset. November 5th 2003 - Just resting and doing some daydreaming of adventures to come. Long way to go yet. Rule #1: Have all your hardware on hand to avoid any unpleasant surprises. I learned my lesson with the galley hurricane hinge when the manufacturer changed the design to zero offset. slides/breaktime.jpg slides/varnished.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 14th 2003 - Three more coats of spar varnish outside which should seal out moisture. November 14th 2003 - Three more coats of spar varnish outside which should seal out moisture. slides/varnished.jpg slides/skin01.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 5th 2003 - The wall skins were roughed out and sandwiched between finished wall & Masonite. Of course I could only route a short distance and then would have to re-arange the clamps. Both aluminum sides were in the sandwich so were cut at the same time. November 5th 2003 - The wall skins were roughed out and sandwiched between finished wall & Masonite. Of course I could only route a short distance and then would have to re-arange the clamps. Both aluminum sides were in the sandwich so were cut at the same time. slides/skin01.jpg slides/skin02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 14th 2003 - Both pieces of rough cut aluminum are sandwiched between finished side and the Masonite template. Then the router with flush cutting carbide cutter was used to finish cut the aluminum. I used a variable voltage supply to the router and cut it to 40 volts to slow the cutter. Any faster and the tool would overheat and melt/ball up the aluminum. November 14th 2003 - Both pieces of rough cut aluminum are sandwiched between finished side and the Masonite template. Then the router with flush cutting carbide cutter was used to finish cut the aluminum. I used a variable voltage supply to the router and cut it to 40 volts to slow the cutter. Any faster and the tool would overheat and melt/ball up the aluminum. slides/skin02.jpg slides/skin03.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 16th 2003 - Straps holding aluminum skin in place while routing the top vent hole with a router flush cutting bit. The top vent will then be drilled and screwed into place which will hold the skin tight. A good idea is to glue something soft to the 2 X 4 blocks to prevent scratching the surface. November 16th 2003 - Straps holding aluminum skin in place while routing the top vent hole with a router flush cutting bit. The top vent will then be drilled and screwed into place which will hold the skin tight. A good idea is to glue something soft to the 2 X 4 blocks to prevent scratching the surface. slides/skin03.jpg slides/skin04.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 16th 2003 - Holding top aluminum in place prior to cutting the top vent opening. Because the sides were clones and the floor was absolutly level when the bulkhead was installed the hard board and aluminum skins then fit pefectly with no trimming. November 16th 2003 - Holding top aluminum in place prior to cutting the top vent opening. Because the sides were clones and the floor was absolutly level when the bulkhead was installed the hard board and aluminum skins then fit pefectly with no trimming. slides/skin04.jpg slides/fender01.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 (INSET) Threaded inserts were installed with allen wrench into the sides for studs to mount fenders. First the blind holes were drilled 5/8" deep and just shy of going through. This leaves a smooth surface on the inside. Inserts (inset) were then screwed in. They were also used to mount the hatch props in the galley. (INSET) Threaded inserts were installed with allen wrench into the sides for studs to mount fenders. First the blind holes were drilled 5/8" deep and just shy of going through. This leaves a smooth surface on the inside. Inserts (inset) were then screwed in. They were also used to mount the hatch props in the galley. slides/fender01.jpg slides/fender02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Ghost image showing how the fender washers will clamp the fender flange. Ghost image showing how the fender washers will clamp the fender flange. slides/fender02.jpg slides/fender03.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Finished mounting and will run beaded fender welting around outside to dress it up before tightening. Finished mounting and will run beaded fender welting around outside to dress it up before tightening. slides/fender03.jpg slides/hatch01.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 8th 2003 - A template was used for the plywood hatch ribs. Pairs will be glued together for each side. When the template is moved in to cut next rib it rough's in the backside of the previous one as it is cut off. November 8th 2003 - A template was used for the plywood hatch ribs. Pairs will be glued together for each side. When the template is moved in to cut next rib it rough's in the backside of the previous one as it is cut off. slides/hatch01.jpg slides/hatch02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 9th 2003 - Detail of how the top is locked into the side ribs with glue and screws. November 9th 2003 - Detail of how the top is locked into the side ribs with glue and screws. slides/hatch02.jpg slides/hatch03.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 9th 2003 - Frame with 1/8" board that will be glued, nailed & screwed into place. November 9th 2003 - Frame with 1/8" board that will be glued, nailed & screwed into place. slides/hatch03.jpg slides/hatch04.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 8th 2003 - Clamping hatch frame in place prior to attaching the hardboard. 1/2" clearance was divided evenly on each side. Note: The bottom bulkhead isn't installed allowing access to remove the clamps when finished. November 8th 2003 - Clamping hatch frame in place prior to attaching the hardboard. 1/2" clearance was divided evenly on each side. Note: The bottom bulkhead isn't installed allowing access to remove the clamps when finished. slides/hatch04.jpg slides/hatch05.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 9th 2003 - Clamped in place on the top prior to gluing on hardboard. November 9th 2003 - Clamped in place on the top prior to gluing on hardboard. slides/hatch05.jpg slides/hatch06.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 9th 2003 - Temporarly removed floor mounting bolt and used hole to clamp bottom of hatch in place prior to skinning with hard board. Note: The bottom bulkhead isn't installed yet which will give access to remove clamps once the skin is installed. November 9th 2003 - Temporarly removed floor mounting bolt and used hole to clamp bottom of hatch in place prior to skinning with hard board. Note: The bottom bulkhead isn't installed yet which will give access to remove clamps once the skin is installed. slides/hatch06.jpg slides/hatch07.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 With hatch clamped in position 1/8" hardboard was glued and tacked with a brad nailer. At the bottom edge it was screwed to the stringer. After skinning with aluminum the top side will have the hinge mounted on top. With hatch clamped in position 1/8" hardboard was glued and tacked with a brad nailer. At the bottom edge it was screwed to the stringer. After skinning with aluminum the top side will have the hinge mounted on top. slides/hatch07.jpg slides/hatch08.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Alright!!! It's starting to look like a real teardrop, not much unlike the one my father bought in the late 1940's. It also served as an extra bedroom which was mine for a few years which was more fun than sleeping in the house. California weather is made for year round teardroping. Alright!!! It's starting to look like a real teardrop, not much unlike the one my father bought in the late 1940's. It also served as an extra bedroom which was mine for a few years which was more fun than sleeping in the house. California weather is made for year round teardroping. slides/hatch08.jpg slides/hatch09.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 January 18th 2004 - Installed these old style hatch props and they have only 9" travel. Mounting was critical as they had zero clearance (inset) when closed. January 18th 2004 - Installed these old style hatch props and they have only 9" travel. Mounting was critical as they had zero clearance (inset) when closed. slides/hatch09.jpg slides/hatch10.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 A piece of poplar was glued and screwed onto the outside rib to have something solid to mount the prop. After fitting it was taken apart to insulate & skin the inside of the hatch. A piece of poplar was glued and screwed onto the outside rib to have something solid to mount the prop. After fitting it was taken apart to insulate & skin the inside of the hatch. slides/hatch10.jpg slides/hatch_hinge.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Details of the waterproof zero/offset hurricane galley hinge. The seal is 7/16" wide extreme weather seal with a hollow core. The aluminum moulding around the galley is the same as the side door jambs and called "Counter top edge". Details of the waterproof zero/offset hurricane galley hinge. The seal is 7/16" wide extreme weather seal with a hollow core. The aluminum moulding around the galley is the same as the side door jambs and called "Counter top edge". slides/hatch_hinge.jpg slides/hatch_hinge02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Another view of the hinge and the ribbed weather stripping to seal out water. All of the aluminum trim on trailer was installed twice. First to fit then removed and the holes and underside of moulding filled with Silicon sealer before re-installed. Excess sealer is easily cleaned off after it sets. Another view of the hinge and the ribbed weather stripping to seal out water. All of the aluminum trim on trailer was installed twice. First to fit then removed and the holes and underside of moulding filled with Silicon sealer before re-installed. Excess sealer is easily cleaned off after it sets. slides/hatch_hinge02.jpg slides/hatch_hinge03.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Be sure to have your hurricane hinge before you finish cut your profile. It's no fun to have to do it again after the walls are up. Be sure to have your hurricane hinge before you finish cut your profile. It's no fun to have to do it again after the walls are up. slides/hatch_hinge03.jpg slides/doors01.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The cut-out for the windows were done with router and template. Aluminum was done at the same time. Trim where the sides meet the roof is called "Regular edge moulding" and bends easily. Was purchased at a local RV repair shop and comes in 16' lengths. It can also be ordered from: http://www.teardroptrailers.net/index.html The cut-out for the windows were done with router and template. Aluminum was done at the same time. Trim where the sides meet the roof is called "Regular edge moulding" and bends easily. Was purchased at a local RV repair shop and comes in 16' lengths. It can also be ordered from: http://www.teardroptrailers.net/index.html slides/doors01.jpg slides/doors02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 December 28th 2003 - The doors were a snap. They were cut out with the router at the same time as the profile and just needed a little cleaning up before installing aluminum and hardware. T-moulding, hinge and window hold skin in place. Also radio antenna was mounted. All the aluminum skin just floats with no adhesive needed. December 28th 2003 - The doors were a snap. They were cut out with the router at the same time as the profile and just needed a little cleaning up before installing aluminum and hardware. T-moulding, hinge and window hold skin in place. Also radio antenna was mounted. All the aluminum skin just floats with no adhesive needed. slides/doors02.jpg slides/profile.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 As shown here the profile was given a 16" flat area to allow for the vent before the ribs were installed. Of course if no vent is used this is unnecessary. As shown here the profile was given a 16" flat area to allow for the vent before the ribs were installed. Of course if no vent is used this is unnecessary. slides/profile.jpg slides/door_spacer.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 On the body side of the piano hinge a 1/8" aluminum spacer (arrow) was installed to space the door out and make room for the door seal. J-moulding was used for a drip rail and also helps hold the aluminum skin tight. On the body side of the piano hinge a 1/8" aluminum spacer (arrow) was installed to space the door out and make room for the door seal. J-moulding was used for a drip rail and also helps hold the aluminum skin tight. slides/door_spacer.jpg slides/door_weatherstrip.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 On the inside hinge side of the door a hollow compression rubber was installed and seals the door water tight even when a high pressure hose is aimed around the outside mouldings. This seal was also used to seal the hatch. The INSTRUCTION plaque is just a Kit Industries copy printed on photo paper. On the inside hinge side of the door a hollow compression rubber was installed and seals the door water tight even when a high pressure hose is aimed around the outside mouldings. This seal was also used to seal the hatch. The INSTRUCTION plaque is just a Kit Industries copy printed on photo paper. slides/door_weatherstrip.jpg slides/door_p_weatherstrip.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The top weatherstrip is called "P-weatherstrip". It's hollow, compresses easily and has a sticky backing making it easy to install. All of my weatherstipping was purchased at the Home Depot. The top weatherstrip is called "P-weatherstrip". It's hollow, compresses easily and has a sticky backing making it easy to install. All of my weatherstipping was purchased at the Home Depot. slides/door_p_weatherstrip.jpg slides/door_latch.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The latch has a 1/4" spacer behind it and the striker plate was made from a piece of 1/8" X 1" angle countersunk for a screw. The aluminum jamb moulding is called "Counter top edging" and can be found at most any hardware store. The latch has a 1/4" spacer behind it and the striker plate was made from a piece of 1/8" X 1" angle countersunk for a screw. The aluminum jamb moulding is called "Counter top edging" and can be found at most any hardware store. slides/door_latch.jpg slides/door_limiter.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 A short piece of nylon strap limits how far the door can swing open. It is turned under at the ends with some metal plates screwing it to the surfaces. A short piece of nylon strap limits how far the door can swing open. It is turned under at the ends with some metal plates screwing it to the surfaces. slides/door_limiter.jpg slides/tail_lights.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 January 18th 2004 - Hatch has 1-1/2" of insulation inside and '39' Ford taillights installed. Clearance lights will also be added in keeping with the DOT rules. January 18th 2004 - Hatch has 1-1/2" of insulation inside and '39' Ford taillights installed. Clearance lights will also be added in keeping with the DOT rules. slides/tail_lights.jpg slides/cooler_in.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The cooler is tapered 4 degrees on the back side so I angled the bottom bulkhead to match which added another inch or two of leg room in the cabin. The cooler is tapered 4 degrees on the back side so I angled the bottom bulkhead to match which added another inch or two of leg room in the cabin. slides/cooler_in.jpg slides/cooler_out.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Cooler tray is made from 1 inch angle with wood trim. Mounted with full extension 100# drawer slides. Cooler tray is made from 1 inch angle with wood trim. Mounted with full extension 100# drawer slides. slides/cooler_out.jpg slides/galley01.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The top galley shelf was made with dados and glue and then set into place for a trial run. After first voyage I was able to remove it to shorten the vertical supports to make better use of the space. The top galley shelf was made with dados and glue and then set into place for a trial run. After first voyage I was able to remove it to shorten the vertical supports to make better use of the space. slides/galley01.jpg slides/galley02.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 A sink large enough to be of much use would take up to much counter space and the depth would restrict the cooler size. Instead I found a plastic kitty litter container that's just the right size for cleaning dishes and it doesn't have to drain under the trailer. A sink large enough to be of much use would take up to much counter space and the depth would restrict the cooler size. Instead I found a plastic kitty litter container that's just the right size for cleaning dishes and it doesn't have to drain under the trailer. slides/galley02.jpg slides/galley03.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Everything stowed and ready for traveling. I stained the inside panel of the hatch dark walnut to add some contrast. The electrical in the hatch connects to the trailer with a flat trailer plug which makes for easy removal of the hatch door in case the hinge track ever needs cleaning. Everything stowed and ready for traveling. I stained the inside panel of the hatch dark walnut to add some contrast. The electrical in the hatch connects to the trailer with a flat trailer plug which makes for easy removal of the hatch door in case the hinge track ever needs cleaning. slides/galley03.jpg slides/galley04.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Finished galley after a few coats of varnish showing cooler extended for easy access and the stove in it's traveling position. Good idea to get a cooler before attaching the bottom bulkhead to make sure you have room. It's critical on an eight footer. A rubber mat is under the stove to keep from harming the countertop while traveling. Finished galley after a few coats of varnish showing cooler extended for easy access and the stove in it's traveling position. Good idea to get a cooler before attaching the bottom bulkhead to make sure you have room. It's critical on an eight footer. A rubber mat is under the stove to keep from harming the countertop while traveling. slides/galley04.jpg slides/stove_drawer.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Details of stove slide in open position. Also a built in drawer underneath for supplies. Dovetain construction was used on the drawers. Details of stove slide in open position. Also a built in drawer underneath for supplies. Dovetain construction was used on the drawers. slides/stove_drawer.jpg slides/galley05.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 First trip out and the galley is open for business for the next nine days. There is a "deep cycle group24 battery" on the floor back under the stove so the trailer can operate under it's own power. First trip out and the galley is open for business for the next nine days. There is a "deep cycle group24 battery" on the floor back under the stove so the trailer can operate under it's own power. slides/galley05.jpg slides/galley06.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The Coleman water bottle just didn't do it for me and was taking up valuable real estate so will haul it in the pick-up. A deep cycle battery was installed on the floor with a removable shelf on top which has lots of room for canned goods. Behind the battery is for propane and anything else that will fit. The Coleman water bottle just didn't do it for me and was taking up valuable real estate so will haul it in the pick-up. A deep cycle battery was installed on the floor with a removable shelf on top which has lots of room for canned goods. Behind the battery is for propane and anything else that will fit. slides/galley06.jpg slides/conduit.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The radius corner moulding is dado'd inside to house seven electrical wires. Also hidden above view is a tube light that gives plenty of light and draws only .7/amp The radius corner moulding is dado'd inside to house seven electrical wires. Also hidden above view is a tube light that gives plenty of light and draws only .7/amp slides/conduit.jpg slides/panel.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 November 17th 2003 - I made the switch plate with a graphics program and printed onto photo paper. Then covered with laminating film to protect and mounted it on a piece of 1/8" Masonite. The lamp above the switches was usually the only light needed for reading. November 17th 2003 - I made the switch plate with a graphics program and printed onto photo paper. Then covered with laminating film to protect and mounted it on a piece of 1/8" Masonite. The lamp above the switches was usually the only light needed for reading. slides/panel.jpg slides/pillows.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The dp/dt switch to open the top vent isn't visible behind the pillow. A reading light and switches to control overhead halo lights, radio and fan. The dp/dt switch to open the top vent isn't visible behind the pillow. A reading light and switches to control overhead halo lights, radio and fan. slides/pillows.jpg slides/inside_shelves.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Finished inside with simple shelves, a built in auto radio and 12V power outlet for TV etc. Although out of sight the stove drawer in the galley butts up to the back of the radio and boxed in. With an eight footer you don't want to waste a single cubic/inch of valuable space. Is it any wonder that in nice weather at home I sometimes spend some nights in the teardrop? Finished inside with simple shelves, a built in auto radio and 12V power outlet for TV etc. Although out of sight the stove drawer in the galley butts up to the back of the radio and boxed in. With an eight footer you don't want to waste a single cubic/inch of valuable space. Is it any wonder that in nice weather at home I sometimes spend some nights in the teardrop? slides/inside_shelves.jpg slides/top_vent.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Just a view of the remote vent with halo lights and fan. The controls are near the pillow on the side wall. Even in 100 plus degree temps I have never found need for the fan especially with both doors are open but of course we're talking about dry California air. Just a view of the remote vent with halo lights and fan. The controls are near the pillow on the side wall. Even in 100 plus degree temps I have never found need for the fan especially with both doors are open but of course we're talking about dry California air. slides/top_vent.jpg slides/jack_spacer.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 I determined that with the jack all the way up and wheel removed that it would still scrape the driveway so a 2-1/2" hardwood spacer was fabricated to give it clearance. The trailer tongue is very short and I don't think there would have been room for a swing away jack. I determined that with the jack all the way up and wheel removed that it would still scrape the driveway so a 2-1/2" hardwood spacer was fabricated to give it clearance. The trailer tongue is very short and I don't think there would have been room for a swing away jack. slides/jack_spacer.jpg slides/dmv.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Here it is all hooked up and ready to take to the DMV for inspection and a license plate so it will have a birth certificate. Here it is all hooked up and ready to take to the DMV for inspection and a license plate so it will have a birth certificate. slides/dmv.jpg slides/my_tear.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 The California DMV issued another plate while this one was being processed. I guess this makes it officially MY TEAR. The California DMV issued another plate while this one was being processed. I guess this makes it officially MY TEAR. slides/my_tear.jpg slides/towel_keeper.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 In a stiff breeze the wind would unroll the towels so a piece of wire from a coat hanger was twisted around a nail to form a spring and screwed to the towel rack to keep tension on the paper. Problem solved. In a stiff breeze the wind would unroll the towels so a piece of wire from a coat hanger was twisted around a nail to form a spring and screwed to the towel rack to keep tension on the paper. Problem solved. slides/towel_keeper.jpg slides/tv_night.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 At night the stove drawer doubled as a TV table although I have since upgraded to a DVD player which draws considerably less current. I think this VHS movie was "Dad" staring Jack Lemmon. Another plus is that the snacks are never far away on these nice warm evenings. And yes, I get a poor grade for housekeeping but this is what bachelor's do. At night the stove drawer doubled as a TV table although I have since upgraded to a DVD player which draws considerably less current. I think this VHS movie was "Dad" staring Jack Lemmon. Another plus is that the snacks are never far away on these nice warm evenings. And yes, I get a poor grade for housekeeping but this is what bachelor's do. slides/tv_night.jpg slides/home_sweet_home.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 Ya got to have pillows and stuff with pictures of the great outdoors on them courtesy of my wonderful sister for remembering my birthday (which I'd like to forget). Sure is a hugh step up from tent camping on the ground. Ya got to have pillows and stuff with pictures of the great outdoors on them courtesy of my wonderful sister for remembering my birthday (which I'd like to forget). Sure is a hugh step up from tent camping on the ground. slides/home_sweet_home.jpg slides/livin.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 This is what it's all about. Just kickin back, listening to the stream and enjoying a place where motor homes and most trailers can just dream about. This is what it's all about. Just kickin back, listening to the stream and enjoying a place where motor homes and most trailers can just dream about. slides/livin.jpg slides/message.php Mon, 28 Jul 2008 12:43:20 -0700 Jalbum 8.0 slides/message.jpg