This is where I left off during the early part of the week with the fuse panel and the charge port and battery charge display mounted in the front cabinet. I wanted to get them mounted as it would be more challenging once the inside roof plywood was installed.
Before I quit for the night Wednesday, I measured out the 5 foot by 5 foot plywood panel that forms the inside skin we will be staring at as ceiling. Of course nothing is completely square so I had to scribe the angle of the back edge which was off by a few degrees of 90. Not a huge deal, you'll never see it as crooked. Then I layed the plywood down onto the ledge across the back and along the right side. I climbed inside and scribed a line on the left side to cut so it would drop down nicely into the rabbited ledge. The seam conveniently falls in the middle of the front cabinet. Fit like a glove. Pretty good for an unsupervised hack. Again nothing burned or blew up. That was quitting time.
A view from inside. The ceiling and outside roof skin plywood is Baltic birch and is lighter in color than the mahogany of the outside walls but once epoxied should be a nice contrast.
Kim came to town early this week and Thursday evening she epoxied the front shelf and dividers. Not afraid to get her hands dirty she is!
Friday evening was grocery shopping at Wegmans and a couple errands and dinner. A mans gotta eat you know.
Saturday morning we took the inner plywood, which was just laying in place, back out and squeezed some PL adhesive in the joint and set it back down in place. For some reason this is much easier with a good looking helper. We brad nailed along the edges and clamped and screwed a few places to hold while the adhesive dried. Taking advantage of the sunshine and blistering heat, we rolled the whole thing outside to dry faster while we made yet another trip for supplies.
The next step to tackle as a Teardrop Team was the lower section of inside plywood. The curvature of this section gets a bit sexier and makes it an all hands on deck and assholes and elbows are pushing and gluing and brad nailing and learning new forms of English swear words as we achieved success. Who knew Kim was so fluent in swearology?! Actually it was not that bad at all. We made a couple of minor adjustments and it went right in.
Luckily in terms of roominess in this tiny trailer, the two of us are not a tall folk. The floor length is only about 5'6". This deluxe step stool should assist us in hopping in😂
Our roof structure is made up of two layers of 1/8 inch Baltic plywood separated by 5/8 inch thick strips of Southern Yellow Pine referred to as "spars". Once we had the inside layer of plywood all glued in place we measured and cut to length the spars which served their start of life as a picnic table that belonged to the fella who started this project. I guess he wanted a camper more than a picnic table. He probably had some splainin' to do when his wife found out but who hasn't found them self in that predicament at least a dozen times. I once turned a delightful playhouse into a lawnmower shed on a whim.
These are the spars all cut to fit and PL adhesived in place. Sorry about your abrupt end to picnics, Larry's wife.
One of the spars wanted to bow and lift away from the plywood so we had to come up with a creative way to apply down pressure while the glue dried.
A simple board wedged from the garage roof truss worked just nicely.
Sunday Kim spread some more epoxy cheer on the doors whilst I started on running wires.
Fuse panel in the front cabinet. This will be hidden behind a door. There's 12 fused circuits in this panel and we'll have ceiling fan, inside lighting, outside lighting, galley lighting, cell phone charge ports, as well as some of the turn signal, brake lights and running lights wiring running through the roof spars. All the spars had holes drilled for wiring before gluing them in place.
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