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Comment: 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.
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.

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:

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.

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.

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.

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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 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.

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.

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.

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.

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Album last updated on Jul 28, 2008 - 12:44 PM
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