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Comment: 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.
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.

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 - 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 - 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.

Wiring for remote vent with fan and halo light. November 3rd 2003
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November 3rd 2003 - Just another view getting ready to install 1/8 top Masonite.

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 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 - 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 - 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.
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