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The Max Bond HTE is typically used in applications that is exposed to high heat. The 1618 is good up to around 250 deg, whereafter it begins to behave more like plastic. All polymers has the same Achilles heal or should I say kryptonite. Heat. As a particular polymer reaches its max temperature...

Out of the oven now cooling down.... Then onwards to the Gas strut brackets. Here are the new hardware ready for trimming tomorrow.

It was however time for the hardware for the gas struts and latch striker plates. Onwards to hardware fabbing. There are again so many different ways to do this. Mine no better that anyone else's. We switch gears and please let me introduce you to Max Bond HTE. It is an epoxy that requires post...

Well it has come down to broom sticks and mop's. Amazon has once again proved to be difficult to predictably order from and here I am still waiting on the latches and gas struts. This will have to do for now.

It is a bit hard to illustrate via pictures, but I thought I give it a go anyway. Remember the lower corners of the door that was trimmed to facilitate the wiper seal.... Perhaps this will give you an idea of the setup. Remember the routing and sanding to make this...?? Here it is from the...

Thank you sir.

Door hinge hardware came in yesterday. Hinge mounted.... From the inside.... Then as we are getting close to mounting the cap It is time to focus on the top coat. The latches wont be here till Monday along with the gas struts and forward window......But it was time to prep the...

Now to a bit of a change in the landscape. As the main pieces has been fabricated and bonded, now we turn our focus on the hardware. The Stainless hardware for the hinge is delayed via USPS but I suppose that was to be expected. Looks like Wednesday for the door mount now. Anyway, no need for...

Last step in finalizing the rear door. Prepping by vacuming the edge/flange that will get a small layer of Thixotropic. Then a small layer of THIX is applied. Now curing. The Stainless hardware should be here Monday so perhaps then or Tuesday I will mount the door. As I turned around, I...

Time to work on the rear door, and its mounting. I take extra time to engineer areas of high stress. I normally build it in the panel in this case when I construct it (them) but as this is made up by non specific pieces I did not have this luxury. As my fellow adventurer pointed out above there...

Correct. That is why I chose the Continuous hinge as it distributes the load very well. One benefit to the use of a carbon matrix is that you can build or engineer the setup in the stress distribution joints. Just screwing a alloy object into a composite anchor will eventually wear beyond its...

Heya Peter. I did this set up (Stainless) on the last box I build with great success. It does however need a primary mean of a seal which is why I used the big wiper seal. Once that is engaged, there will be no dust from this orifice. Plenty other places ha ha ha, but not here. I am a big fan of...

Then it was back to the door. Began routing out the foam in two stages..... Then filled the void with a small layer of Thixotropic then a strip of Carbon Fiber strip from the left over pile. This is to strengthen that whole flange as the continuous stainless hinge will mount to that...

Then the corners were trimmed with a dremmel and a sanding block.... Door was test fitted on the shell and it works perfect. Now it was time to set the camper down on the truck bed. I was by myself, but @ 37 pounds.....not hard to do. She fits beautifully.....

And today was the day it all came to fruition. Well.... Thats not entirely true, but I got to put it on the truck to have a look. Pics coming shortly.

It has been weighed......... Il take guesses.....:LOL::geek:.

Then comes chapter two in the "there is an epoxy for every job" installment. Now we dive deep in to the book of "1001 composite ways of the garage gangster". Were way in the now. I present to you one of the best epoxys for this job..... Ta-daaaaaaaa..... Ok, now after you have wiped the...

Weighed the shell...... Still taking wagers, or guess. After the main door has cured, it was then time to engineer the bottom flange. I have never been a fan of how the industry does the bottom flange on the shells. In trying to keep water out many have a plastic flapper molded to the bottom...

I think it is........ I have a fish weight and a scissor lift.... What could go wrong... Ha ha ha

On another note....... Il take wagers guessing the weight of the box. Lest leave the rear door off as in order to install it there will be a 48 inch Stainless continuos hinge and two gast struts and push locks involved. For the record, I have not weighed it yet, but all I can think of is the...