Sunday 22 March 2020
More wall construction and the floor
Once all sections of the wall were complete the skins were trimmed back to the size of the original frames with a trim router.
..and fitted back into the metal framework.
The external ply was left uncut with the exception of the rear window and door. These cutouts will be made once fully ready to fit the windows. The wooden frames provide a guide for the trim router and the internal wall panels were trimmed back to the frames.
Floor construction method was similar but this had to be built in situ. Underside of the lower floor panels was varnised before fitting.
The external ply was left uncut with the exception of the rear window and door. These cutouts will be made once fully ready to fit the windows. The wooden frames provide a guide for the trim router and the internal wall panels were trimmed back to the frames.
Floor construction method was similar but this had to be built in situ. Underside of the lower floor panels was varnised before fitting.
It is worth noting for historical context that at this stage of the project the coronavirus outbreak was starting to take hold. We decided to move ourselves and the project bac to the UK since it was uncertain how long this problem would last.
There are not many photos of the next few days of work. Time was a bit pressing.
The roof was installed. 6mm marine ply screwed directly to the metal frame and sealed all round with Sikaflex. Wall panels were sealed and screwed in place.
We then loaded it up.
... and set out for home.
Wall panel construction
A bit of a catch up.........
We moved the project to a warmer and drier part of the world to continue the work.
The frame was deomounted and painted with hammerite.
The side walls are to be comprised of 3 panel sections, laminated with a 40mm PIR insulation core, internal wall of 4mm ply, external wall of 6 mm marine ply.
Methodology.
Construct a light wooden frame within the metal frame.
This creates the 3 wall sections which can now be removed to apply the internal and external skins.
Glue is applied. The skin ply place in position and the section placed in the improvised press while the glue cures.
Turn over and apply the other skin using the same methodology. Shallow holes were made in the insluation board to provide a key for the expanding foam glue.
We moved the project to a warmer and drier part of the world to continue the work.
The frame was deomounted and painted with hammerite.
The side walls are to be comprised of 3 panel sections, laminated with a 40mm PIR insulation core, internal wall of 4mm ply, external wall of 6 mm marine ply.
Methodology.
Construct a light wooden frame within the metal frame.
Use this frame to size and mark the insulation material.
Cut the insulation to size and fit inside the wooden framework. Glue with expanding foam glue.
Once the glue has cured mark and cutout frames for windows and hatches
Glue the frames in position
This creates the 3 wall sections which can now be removed to apply the internal and external skins.
Turn over and apply the other skin using the same methodology. Shallow holes were made in the insluation board to provide a key for the expanding foam glue.
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The drawings: One of the other objectives and reason that the camper is planned as a demountable is that vehicle and unit will fit int... -
Once all sections of the wall were complete the skins were trimmed back to the size of the original frames with a trim router. ..and... -
Further work on window installation I have installed a trim above the window to protect the top seal from water flowing down the walls...