FORMING MAIN WALLS

RAW ALUMINUM

ALL PIECES CUT AND NUMBERED FOR WELDER. MAIN STRUCTURAL PIECES 1" X 1" 1/8TH WALL. iNTERIOR (NONSTRUCURAL = 1/16TH WALL THIN)

OFF TO WELDER

JIGGED AND READY

HOME AND FIRST TILT UP

GRINDING DOWN BEADS IN CORNERS WHERE DOOR WILL GO

ROUGH SCUFF IN AND OUTSIDE FOR ADHESIVE BONDING

FORMING FRONT ROUND CORNERS FROM FOAM

SCREWED AND GLUED ON

 HI TENSILE 1" PINK FOAM

THE REAR VESTIBULE LOWER CROSS PIECE HAS TO BE COUNTERSUNK FLUSH

SCREWS SO DOOR WILL CLOSE. THE OTHER PANELS CAN BOLT TO FRAME.

INSIDE WALL AND ROOF INSERT WILL BE SECURED WITH SCREWS

FROM OUTSIDE. HAVE TO BE COUNTERSUNK FLUSH SO NOT PROTRUDE

AGAINIST ALUMINUM OUTER SKIN. DRILL SLOWLY AND CAREFULLY IN STEPS.

NOTICE LITTLE TOOL GAUGE I MADE TO DEPTH MEASURE EACH ONE.

WHILE I WAS AT IT, I ADDED A COUPLE OF EXTRA PIECES IN CASE I EVER WANT TO DO A SET OF CROSS ROOF MOUNTS

CANVAS INNER WALL SKINNING. TIP, HAVE PLENTY OF CLAMPS AND HAVE THEM ORGANIZING FOR QUICK GRABBING. PROCEDURE: CUT FABRIC ROUGH SHAPE. ALLOW SEVERAL INCHES ALL THE WAY AROUND. STRETCH WELL AND CLAMP ONE END. FLIP FABRIC BACK EXPOSING FRAME MEMBERS. SPRAY WITH ADHESIVE. I USED 3M #71. LET SET TILL TACKY. CAREFULLY LIFT FABRIC NOT LETTING IT TOUCH. PULL UP AND LENGTHWISE UNTIL GOOD AND TAUT THEN LAY DOWN AND CLAMP IN CENTER. GO TO EACH SIDE, PULL TAUT SET AND CLAMP IN CENTER. PROCEED IN A PATTERN OF STRETCHING AND CLAMPING IN CENTERS UNTIL ALL WRINKLES ARE OUT. GO AROUND A COUPLE OF TIMES LET SET. ONLY SPRAY AND CLAMP THE TOP

FRAME ALUMINUM SURFACE. WEARING RUBBER GLOVES RUN THUMB AROUND PRESS SQUEEZE GLUE AND FABRIC UNTIL GLUE SQUISHES UP INTO AND SATURATES FABRIC. LET DRY. TURN OVER, REMOVE CLAMPS. SPRAY ADHESIVE AND I" OF FABRIC ALL THE WAY AROUND. LET GET TACKY THEN FOLD FABRIC OVER AND ATTAIN A BOND OF THIS SECOND SIDE. GLOVE AND SQUISH. LET DRY WELL.

RAZOR BLADE OFF EXCESS FABRIC. YOU SHOULD HAVE A STRONG 2 EDGE BOND. IN A WARM TEMP USE A HAIR DRYER OR IRON TO PASS OVER ENTIRE FABRIC LETTING IT DRAW VERY TIGHT. i USED A HEAT GUN FROM HARBER FREIGHT. VERY HOT AND HAD TO KEEP MOVING SO AS NOT TO SCORTCH...BUT IT WORKED GREAT. THIS IS HOW LIGHT AIRCRAFT ARE SKINNED. I THEN COATED WITH OLD FASHIONED AEROPLANE (NITRATE) DOPE TO FURTHER DRAW AND TIGHTEN. I DON'T KNOW IF YOU CAN STILL BUY THE STUFF. THEN A GOOD COAT OF PRIMER AND A COUPLE COATS OF GLOSS WHITE FOR MY LIGHT INTERIOR.

SIDE WALLS WEIGH 22#'S PER SIDE

MORE ON WALL SKINNING ON THE INSIDE WALLS SEGMENT