1 Bored Clerk's Garage Built Camper

I think the way you are going will net a better finished result.

 

I think so. It should be stronger and serviceable should I need to replace the door or the hinge for some odd reason.

 

I always over build everything, just in case...

 

Status update:


Sanded these smooth again after the epoxy cured. Then I re-drilled the holes to the smaller size necessary to fit the furniture nuts. This way, the entire hole is coated in a solid layer of epoxy and the barrel of the furniture nut is isolated from the wood. Also, if you’re doing a string of holes in something, set up a fence! It keeps things much more consistent.


Re-drilled and ready for insertion! Before inserting all of the furniture nuts, I coated the entire back with epoxy. This will help set the furniture nuts and protect the wood as much as possible.


Using the drill press for pressing instead of drilling. This makes life easy and makes sure everything goes in nice and straight.


And, here we are. 36 stainless steel furniture nuts set and curing in place. Once cured, I’ll go back in and sand off the edges of the nuts that overhang the edge. Should be ready to test fit at that point! Hopefully they’ll cure by late this afternoon. It’s a bit cold right now so who knows.

 

Bring them inside! This is important! Damnit!

 

My lovely wife is ever so supportive of my projects but accidentally gluing scraps of plywood to the dining room table may not go over so well.

 

Putting them near a little heat.

 

Good compromise
I have built a paint/vapor booth in the basement for applying stain and varnish. 4" dryer vent, lots of plastic, Gorilla tape and an old water heater direct vent fan.

 

That sounds like a great setup! If you can paint and varnish in the same building you live in and not have it be awful, you’re doing well!

 

It really makes me miss having a garage. At this time, this is the best option.

Take note future self: If I ever renovate the house I'm also living in... I better have a detached garage.

 

Good night of work!


Trimmed all of the furniture nuts so they’re not hanging off the edge.


Then I attached the hinge. Everything looks good!


Routed out the edge of the door frame for the hinge plate.


A little trimming and the hinge will fit just right.


I also got the door panel cut!

Hoping to have a door that swings on it’s own hinge this weekend.

 

I’ve been really sick for the past week. But I’m over the hump and on the feeling better side now.


Grab some wax...


Screw some fasteners into the furniture nuts from the front. Use the wax to completely cover the back of the fasteners and fill in all of the threads. This is so that all of the epoxy won’t ooze into the threads and foul then and/or glue your fasteners into the furniture nuts. Go back and carefully use acetone or some other wax remover to clean up any wax that’s outside the hole. You want as much epoxy to part contact as possible.


Then I COMPLETELTY filled all of the voids in the honeycomb in the area that’s been routed out. Press the hinge plate into place and use tape to hold it in place. I was really careful here to keep the plywood strip as even, plumb, flat as possible so that the hinge would work properly. I won’t know for sure until the door is done and in place.


There it is!


Now I just need to go in and clean up all of the edges, fill any voids, route the edge for fiberglass. But that will all have to wait until I get the door side done and I can test the hinge.


I had rough cut the door earlier. This morning I routed out the recess for the hinge plate just like on the camper. Then I followed the exact same process for epoxying this in place. I had more clamping options on the door so I took advantage of them. I needed to keep the door edge flat and true so I clamped a big piece of angle aluminum to it. Then I pressed the hinge plate into place with tons of epoxy. Then I used a second piece of angle aluminum to hold the hinge plate square to the edge of the door. I pulled up and pushed down on the hinge plate to get it as true to the door face as possible. It’s, of course, not going to be perfect. I just need it perfect enough to not bind the hinge! So, that’s where I’m at for today. It’ll take several hours for that epoxy to cure. I may be able to cut the door to its final shape (rounded corners) today and test fit it but it may have to wait until tomorrow. We’ll see. I’m taking a sewing class this afternoon so several hours will be taken up with that!

 

Just catching up in here. Progress is looking great! Glad to hear that you are feeling better

 

Door!



The gap is bigger than I need and the corners aren’t concentric but I think I’m just going to roll with it. I may get in there and build up the most offensive corner and leave it be.

 

The edge will have rounded edges on both faces and will be fiberglassed for strength.

 

Seems to swing fine. I was worried about that too but it seems okay!

 

What latch are you intending to use? Screen door latches seem like good choices for items like this, and then there are RV style surface mount latches too...

 

I already bought my latch...there’s a photo of it back in this thread several pages back. It’s a southco latch that locks/unlocks and opens from both sides. It’s pretty nice, I think. I’ll be working out it’s location on the door this week so you’ll see it again soon!

 

12 pages back! JP

I forgot this posting but I see you made a good latch choice!

 

Thanks! Yeah, it seemed like a good choice. Now to figure out how to actually implement it.