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Comment: 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.
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 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.

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.
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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.

Cooler tray is made from 1 inch angle with wood trim. Mounted with full extension 100# drawer slides.

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.

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.

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