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Comment: Ghost image showing how the fender washers will clamp the fender flange.
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 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 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 - 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.

(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.

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Finished mounting and will run beaded fender welting around outside to dress it up before tightening.

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 9th 2003 - Detail of how the top is locked into the side ribs with glue and screws.

November 9th 2003 - Frame with 1/8 board that will be glued, nailed & screwed into place.

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.

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