Don starts buttoning her up (split from Re: What did you do to your coach)

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Don starts buttoning her up (split from Re: What did you do to your coach)

March 18, 2013, 10:01:11 pm

Epoxied on the bottom fiberglass skin of the utility compartment on our coach. Actually, the glue up was last night and the finish up was today. Most of you probably thought this was done a long time ago... But I finally finished all the preparations I could do and decided that it was ready. What a job! It was the most physically demanding part of the project yet. Once you start, you can't stop! Because that glue is setting up, and thank God for slow setting hardener. I'm so glad that I decided to do this part ( about 4 1/2' X 8') first rather than the larger 8' x 14' section to come. Most of the difficulty is the sheer area of adhesive that needs to be applied combined with the fact that you're going against gravity. Anyway, I'm happy with the outcome... Here are some pictures for your enjoyment.

Made you even more glad that you're not me, didn't it?

Don

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #1 – March 18, 2013, 10:12:48 pm

Quote from: "acousticart"

Epoxied on the bottom fiberglass skin of the utility compartment on our coach. Actually, the glue up was last night and the finish up was today. Most of you probably thought this was done a long time ago... But I finally finished all the preparations I could do and decided that it was ready. What a job! It was physically demanding part of the project yet. Once you start, you can't stop! Because that glue is setting up, and thank God for slow setting hardener. I'm so glad that I decided to do this part ( about 4 1/2' X 8') first rather than the larger 8' x 14' section to come. Most of the difficulty is the sheer area of adhesive that needs to be applied combined with the fact that you're going against gravity. Anyway, I'm happy with the outcome... Here are some pictures for your enjoyment. Made you even more glad that you're not me, didn't it? Don

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #2 – March 18, 2013, 10:20:57 pm

Don,
I'm dead tired just looking at the pictures. What a great looking job you've done on this coach. Keep it up and before you know it, it will be ready to enjoy for many more miles.
Peter

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #3 – March 18, 2013, 10:23:50 pm

Beautiful job! Gives new meaning to the old woodworker's expression "you can never have enough clamps."

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #4 – March 18, 2013, 10:24:29 pm

Excellent work (as usual).

Brett

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #5 – March 18, 2013, 10:54:08 pm

Thanks guys! Makes me tired to look at the pictures too... Yeah about the clamps, that's an expression I live by and you can bet that I rounded up every single clamp that I could find for this job!

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #6 – March 18, 2013, 10:55:26 pm

Don I have a few more clamps you could have used. I have a tip for you, turn the coach over it makes it a lot easier!!!
Well done, looks good. Leave the bay doors off so your workmanship can be viewed.
John H

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #7 – March 19, 2013, 01:23:18 am

Looking good Don ! Looks like it's all starting to come together.

Richard B.

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #8 – March 19, 2013, 07:58:24 am

Don, When you get all this work done it will be a shame to drive it and get it all dirty. Maybe you should exhibit it somewhere. But then you would not have the fun of using it. Great Job.
Gary B

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #9 – March 19, 2013, 11:31:29 am

Gary,
Thanks, but all things considered, I can't wait to get it dirty!

Don

Quote from: Gary Bouland – March 19, 2013, 07:58:24 am

Don, When you get all this work done it will be a shame to drive it and get it all dirty. Maybe you should exhibit it somewhere. But then you would not have the fun of using it. Great Job.
Gary B

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #10 – March 19, 2013, 11:38:17 am

Thanks Richard,
Yes it really feels like it's starting to gel. Putting the skin on represents a commitment... because from that point on, god willing, I'll never have to look at that part of the coach again and so it is as done as it's ever going to get!
Don

Quote from: rbark – March 19, 2013, 01:23:18 am

Looking good Don ! Looks like it's all starting to come together.

Richard B.

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #11 – March 19, 2013, 11:56:01 am

With the quality work you are doing Don I doubt anyone following you on the highway will have a big piece of Fibreglass flying into their windscreen from under the coach !
I noticed the strip of flatbar bolted across one of the box sections, did you put that on first or did you secure it after you jacked up your plywood "press" as I was thinking that making a "frame with 2x4 sides as well as cross ones instead of all the clamps, may have been easier for you. You can still put a few clamps along it. You did a great job, and I bet it was a hectic 30 mins or so making sure it was square and flat before the panel started sticking?
John H

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #12 – March 19, 2013, 12:24:57 pm

LOL! I don't think anybody will have a big piece of fiberglass flying into their windshield from under my coach... But if they did, I would surely be able to see it in my high definition backup camera

The flat stock is 1/8" thick stainless steel that I'm basically using as a giant washer to distribute the clamping force of the roloks. The wider piece of flat stock is 4 inches wide and covers the seams where I have to join the new skin with the old skin. I think the hardest part of that aspect of the project was getting all of the holes accurately drilled in the new skin and in the stainless flat stock. The good news is that with so many holes, the placement of the skin is not open to question. When the bolts go through, the skin is on square. The two plywood platforms that I made to use as clamping cauls fit between the stainless steel flat-stock/washer and I didn't want to use cross pieces of 2 x 4 because it would be difficult to keep it flat and I figured that keeping the plywood flexible in one direction would allow me to compensate for any warping of the plywood, since the basement framing is quite flat and square. Also cutting it into 2 foot wide sections made it a lot easier to handle then a big 4 x 8 piece would have been. I wrapped the tops of the plywood platforms with polyethylene plastic to keep the epoxy from sticking the platforms to the bottom of the coach.
Don

Quote from: John Haygarth – March 19, 2013, 11:56:01 am

With the quality work you are doing Don I doubt anyone following you on the highway will have a big piece of Fibreglass flying into their windscreen from under the coach !
I noticed the strip of flatbar bolted across one of the box sections, did you put that on first or did you secure it after you jacked up your plywood "press" as I was thinking that making a "frame with 2x4 sides as well as cross ones instead of all the clamps, may have been easier for you. You can still put a few clamps along it. You did a great job, and I bet it was a hectic 30 mins or so making sure it was square and flat before the panel started sticking?
John H

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #13 – March 20, 2013, 12:08:22 am

Today I bolted the bulkhead together. Hopefully for the last time ever! I had previously fabricated the trim piece out of 1/8 inch aluminum angle and today I installed it in the bulkhead joint with polyurethane roof flashing sealant. I laid a bead inside the angle between the fiberglass and the aluminum as well as inside the compartment between the bulkhead and the transverse frame member. I got a nice squeeze out of the polyurethane sealant when I torqued the bolts down lubricated with an American Racing Product called Ultra-Torque. Pictures below...
Don

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #14 – March 20, 2013, 09:32:16 am

I wonder if there is support for creating a separate forum topic for Don's (Acousticart) bulkhead project. It is so interesting and complex and I think a single thread detailing the project would be great. I can imaging many searches on different aspects of the job.
jor

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #15 – March 20, 2013, 10:11:39 am

Here are a couple of earlier topics for anyone who needs to catch up

Before, During, After

Chassis construction photos from Don and welding on your FT

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #16 – March 20, 2013, 11:03:17 am

Don & Tys,

This is super!!!

What's the chances you can join us for the pair of California Chapter Spring Rallies:
05/02/2013 - 05/05/2013: Gold Country Rally

and the

05/06/2013 - 05/09/2013: 'Stuck in Lodi' Rally?

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #17 – March 20, 2013, 02:46:55 pm

And I though Norm Abram was the King of clamps. Looking good. What's that under the bolt heads?GAM

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #18 – March 20, 2013, 03:07:51 pm

He probably does have more clamps than me...

I'm not sure what picture you're referring to Joseph, but in the picture of the bulkhead joint itself there are reflections of the bolt heads on the shiny paint (POR-15) on the angle iron. In the picture that's taken from underneath utility compartment, there's a piece of stainless steel flat stock underneath the rolok screws.
Don

Quote from: gam – March 20, 2013, 02:46:55 pm

And I though Norm Abram was the King of clamps. Looking good. What's that under the bolt heads?GAM

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #19 – March 20, 2013, 05:39:20 pm

Very Impressive!

Factory will be looking to employ you.

Keith

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #20 – March 20, 2013, 05:41:26 pm

That is impressive. Well done.

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #21 – March 20, 2013, 05:53:14 pm

Thanks Harvey! I wish we could, but it is just not in the cards this year. As soon as I can get the plumbing working (I.e., put the tanks, pump, water heater, etc.), I will be staying in the coach while I prep the house to sell as soon as practical (before the market tanks again...). So even though I believe with all my heart that the coach will be capable of a trip like that, we will be limited short local excursions until the house sells. We are looking forward to our first real FT rally (one where we have the coach with us!), I just don't know when that will be. Maybe Quartzsite if there is a rally next year... Sigh

Don

Quote from: Harvey Nelson – March 20, 2013, 11:03:17 am

Don & Tys,

This is super!!!

What's the chances you can join us for the pair of California Chapter Spring Rallies:
05/02/2013 - 05/05/2013: Gold Country Rally

and the

05/06/2013 - 05/09/2013: 'Stuck in Lodi' Rally?

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #22 – March 20, 2013, 06:04:30 pm

Thanks Michelle! I'll use this topic for further posts as I proceed on the project.
Don

Quote from: Michelle – March 20, 2013, 10:11:39 am

Here are a couple of earlier topics for anyone who needs to catch up

Before, During, After

Chassis construction photos from Don and welding on your FT

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #23 – March 20, 2013, 07:40:31 pm

Don,

I just followed the links that wonderwoman Michelle put up of all your work done before I found this forum. It is truly impressive to see the high quality, extensive work put into your rig. It should last forever. Thanks for answering my PM last night also. You are a big encouragement for myself and others here. Keep up the great work.

Larry

Re: Don starts buttoning her up (split from Re: What did you do to your coach)

Reply #24 – March 24, 2013, 10:26:06 pm

Made some more progress in the last few days... Here are pictures of some of it. I installed the aluminum plates which I fabricated much earlier in the project and bedded them in polyurethane roof flashing cement. Messy business that! After the polyurethane cement cured, with the help of Richard Bark from the forum, rolled Epoxy mixed with extra slow hardener and filler and installed the top fiberglass skin (actually the floor of the compartment) in the utility bay. Since the compartment divider was still in the compartment and the bulkhead was already bolted together, this was easier said than done. Once again, most of my clamps of all descriptions were put into play! I will leave it clamped for a day or two before I remove all the clamping cauls. I was very happy to note that all of the holes drilled in the fiberglass skin lined up nicely with those in the framing and presented no alignment issues. Using the ~~bottle of Jack~~

to push the plywood platform down in the middle was Richard's idea. Thanks Richard! I am confident that I will never have to see that basement framing again... almost a shame, but I can live with that!

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