PaulJensen
Custom Builder
Close...Router jig and a file...
EarthRoamer XV-JP "Northwest Edition"
- Thread starter WhereTheHellIsJames?
- Start date
Close...Router jig and a file...
PaulJensen
Custom Builder
Thirty-Seven...
Thirty-Seven...
(above) The propane locker has been fiberglassed for a few weeks now, so I sanded the bumps, and...
(above) ...installed the Thermo-Mat insulation ...Nice touch I must say...
(above) Next, I cut some plywood to make a roll-bar cover / shelf / LED light mount...
(above) Then the cab-over bed front panel got worked...
You can see that bolts were ground flush...The piano hinge is set in a slot cut into the edge of the plywood so it can have the thickness I want and still be able to fold enough...The 8/32 bolts sandwich the hinge between the plywood...
In the picture above I just finished cutting a slight arch at the bottom of the panel...The arch was scribed from the steel frame just behind the front seats...That area behind the seats serves as a pass-through so having it be as open as possible is important, thus an arch, not a flat cut...
(above) Only the bed pull-out portion of needs to be hinged, so a cut was made in the ply and the hinge, then a piece of 1/4" plywood was cut to back up the non-hinging part...
(above) Glued then stapled...
(above) Next two strips of 1/4" zebrawood were glued then ...
(above) ...clamped to the bottom of the arch...The scrap, cut-off piece is used to create even clamping pressure over the curve...
(above) While waiting for that to set-up I glued and pin-nailed a teak strip on top of the roll-bar cover...
(above) While waiting for those and the bed panel to set-up, I found a scrap piece of 2 x 4 rectangular aluminum and made a few cuts with the tablesaw, then tacked the cut-off piece to the inside...This will be the replacement part of the drop-down step that broke yesterday...I'll take it to an aluminum welder to complete the fabrication...
(above) Got these installed...
(above) Some rough sanding got done, then the bed panel was loose set, then the roll bar covers were test fit...
(above) I like 'em...Tomorrow they'll get veneered and firmly set...
(above) The roll bar shelf should be pretty useful...Once you're set up for camping, it provides a great place to put things up, out of the way...like a beer...
More tomorrow...
Thirty-Seven...
(above) The propane locker has been fiberglassed for a few weeks now, so I sanded the bumps, and...
(above) ...installed the Thermo-Mat insulation ...Nice touch I must say...
(above) Next, I cut some plywood to make a roll-bar cover / shelf / LED light mount...
(above) Then the cab-over bed front panel got worked...
You can see that bolts were ground flush...The piano hinge is set in a slot cut into the edge of the plywood so it can have the thickness I want and still be able to fold enough...The 8/32 bolts sandwich the hinge between the plywood...
In the picture above I just finished cutting a slight arch at the bottom of the panel...The arch was scribed from the steel frame just behind the front seats...That area behind the seats serves as a pass-through so having it be as open as possible is important, thus an arch, not a flat cut...
(above) Only the bed pull-out portion of needs to be hinged, so a cut was made in the ply and the hinge, then a piece of 1/4" plywood was cut to back up the non-hinging part...
(above) Glued then stapled...
(above) Next two strips of 1/4" zebrawood were glued then ...
(above) ...clamped to the bottom of the arch...The scrap, cut-off piece is used to create even clamping pressure over the curve...
(above) While waiting for that to set-up I glued and pin-nailed a teak strip on top of the roll-bar cover...
(above) While waiting for those and the bed panel to set-up, I found a scrap piece of 2 x 4 rectangular aluminum and made a few cuts with the tablesaw, then tacked the cut-off piece to the inside...This will be the replacement part of the drop-down step that broke yesterday...I'll take it to an aluminum welder to complete the fabrication...
(above) Got these installed...
(above) Some rough sanding got done, then the bed panel was loose set, then the roll bar covers were test fit...
(above) I like 'em...Tomorrow they'll get veneered and firmly set...
(above) The roll bar shelf should be pretty useful...Once you're set up for camping, it provides a great place to put things up, out of the way...like a beer...
More tomorrow...
Last edited:
westyss
Explorer
Excellent work you two, great design and great construction techniques, this gives me motivation to get my interior finished too, unfortunately it wont be as nice as this
Paul, I like your way of making drawers with the dado like corners, I might try that, thanks for sharing with us, keep up the good work! Looking forward to seeing the final result.
Paul, I like your way of making drawers with the dado like corners, I might try that, thanks for sharing with us, keep up the good work! Looking forward to seeing the final result.
mhiscox
Expedition Leader
There must be an optimum response to this comment, but damned if I know what it is.
GR8ADV
Explorer
After all that has been done and said, this was the best post in the thread. :sombrero:
PaulJensen
Custom Builder
Thirty-Eight...
Thirty-Eight...
(above) Friday...The list grows and gets lined out, then grows again...
(above) Behind the passenger seat was unfinished...
(above) There was one full panel of the InsulMat left...The printing wasn't wanted where this would get installed, so it got wiped off with lacquer thinner...
(above) Installing this stuff is getting even easier...Peel and stick, trim in place, press hard then onto the next task...I like all the bright metal back here...
(above) Shiny and a bit more soundproof...
(above) At the end of that cabinet, this drop-leaf extension was mounted...The 14" length added to the 60" curbside bench makes a respectable length for a bed inside a Jeep...
(above) Next the teak baseboard under the driver side cabinet was prepped, poly-u-glued, then put in place...
(above) ...then the teak floor panel was slid in and 1/8" shims were placed to push the base, straight...
(above) I gave the 40 grit sanded teak floor a wipe with paint thinner to get an impression of the finished color...
(above) The roll bar covers were veneered and dry fit again...Notice the shape of the bed-panel up front...It gets changed next...
(above) That angle once veneered would have looked awkward...But, if the panel is moved 1/2" to the rear, the panel sides can be vertical...Once it gets veneered it will have a better visual balance...
(above) Like this...The area above the hinge is where the sliding bed is and to keep it from sliding while driving, the panel will latch in place and keep the bed from slamming back and forth...The venner was put on, in place then trimmed with a knife...
(above) I put some carpet on the roll bar shelves...
(above) Looking good...Maybe better than good...
(above) But still a lot of details to finish up next week...Hopefully...
More later...
Thirty-Eight...
(above) Friday...The list grows and gets lined out, then grows again...
(above) Behind the passenger seat was unfinished...
(above) There was one full panel of the InsulMat left...The printing wasn't wanted where this would get installed, so it got wiped off with lacquer thinner...
(above) Installing this stuff is getting even easier...Peel and stick, trim in place, press hard then onto the next task...I like all the bright metal back here...
(above) Shiny and a bit more soundproof...
(above) At the end of that cabinet, this drop-leaf extension was mounted...The 14" length added to the 60" curbside bench makes a respectable length for a bed inside a Jeep...
(above) Next the teak baseboard under the driver side cabinet was prepped, poly-u-glued, then put in place...
(above) ...then the teak floor panel was slid in and 1/8" shims were placed to push the base, straight...
(above) I gave the 40 grit sanded teak floor a wipe with paint thinner to get an impression of the finished color...
(above) The roll bar covers were veneered and dry fit again...Notice the shape of the bed-panel up front...It gets changed next...
(above) That angle once veneered would have looked awkward...But, if the panel is moved 1/2" to the rear, the panel sides can be vertical...Once it gets veneered it will have a better visual balance...
(above) Like this...The area above the hinge is where the sliding bed is and to keep it from sliding while driving, the panel will latch in place and keep the bed from slamming back and forth...The venner was put on, in place then trimmed with a knife...
(above) I put some carpet on the roll bar shelves...
(above) Looking good...Maybe better than good...
(above) But still a lot of details to finish up next week...Hopefully...
More later...
WhereTheHellIsJames?
Explorer
Sheesh, this has got to be the longest thread I ever started...
Paul- Great work! Let me know if you'd be interested in teaming up on another project.
Mike- When do we get to see the finished product? This year's OvEx might be a great venue for an unveiling
Paul- Great work! Let me know if you'd be interested in teaming up on another project.
Mike- When do we get to see the finished product? This year's OvEx might be a great venue for an unveiling
Seems a bunch of weight was pulled out also- could be a wash
PaulJensen
Custom Builder
Paul- Great work! Let me know if you'd be interested in teaming up on another project.
Mike- When do we get to see the finished product? This year's OvEx might be a great venue for an unveiling
Hi J...
I'm interested, for sure...
It's likely that I'll bring it to Flagstaff if that's what you're talking about...Is there a link for it...???...
Overland Hadley
on a journey
I have been wondering this as well. Teak and copper are not light items, but man is it beautiful.
PaulJensen
Custom Builder
The quantities are pretty small...Visually it has weight, but physically not so bad...The zero to sixty figure shouldn't be too adversely affected...