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So... the verdict is in. The old tongue box weight was 62 pounds and the steel plate 25 pounds for a total of 87 pounds dead front weight. The new composite twice as big tongue box weight is 45 pounds. It is a few pounds more that I thought but as it is twice as big, a 50% in weight reduction is...

It........is...... fiiiiinisshed....... whooooheeeee. All I had was gloss uv protective urethane coat. So I tinkered a bit with flow pattern, volume and rate. You can push a bit more air and less liquid. Sorta like a bit drier..... and the gloss has a bit of texture or should I say satin finish...

You are correct. The piece was bonded on the whole surface (3mm thick) on to the top lid. Here it is with the added side brace.

And so..... here is the latch for the lid.

It made me smile.... :):) I am on the end sprint now. The latch was almost finished today. It is curing now, and will just need a bit of trimming tomorrow, with an added side brace. It has been a long journey, but as with my projects, they tend to reward me well... :). I suspect that I will...

I did consider that but as I feel quite comfortable working the composite latch, I went that route. The heavy'er weight would not concerned me. What always is a concern when mixing alloys and composites are two main areas. Bonding and galvanic corrosion. Granted..... you could bolt the latch to...

Work begun on the lid latch..... step number one.... proof of concept then make sure it is going to be strong enough.

Side armor...… Very important this is....Hrmmmmmm… :) :)

Lock mounted. Now I have to fab the latch that mounts to the lid.

At some point I am going to change that front stabilizer jack. There is a lot of flex and torque on that design. Specially as stock. With the new CF box I estimate I am about 150 pounds of tongue weight, almost half of what it was stock, which puts me right at about 10%. When all set and done, I...

Almost done. I went with Gas strut on one side only, as the smallest 15 inch'ish unit I could find on Flamazon was 22.5 pounds. I think the lid is about 3-4 pounds, and I don't want the lid to eject the solar panel when opened.... Ha

I am almost done with the Carbon fiber/kevlar tongue box build. It is mounted on a honeycomb composite plate. The unit it replaced was also sitting on a steel plate.

The new grill were purchased for the exact dimensions. As sleeping bags will now reside in the front tongue box instead of the back, the kitchen utensils were moved back in the rear of the trailer along with the yammi generator. That freed room up on top of the stove drawer to finally house the...

Looks like they also added gaskets to the tongue box bolt downs..... and a few more bolt down behind that.

I think it is an oddball size just under 2 inches. When I welded my front crossbar it was the case. Local steel mill had it though.

The lid is being mounted. 2 inch stainless hinge. Now trying to gauge the size and location of the gas struts.

I had mine in the garage for about a year, but now it is in the hanger. I had no issues in the garage.

That is great to hear.

Might want to consider welding that. You can prop find a shop that will be happy to oblige.

Fully agree. I have often wondered why not more planes are welded...... but I think rather than a lag of longlegivity..... it is so parts can be unbolted or rivited and replaced. Lots of great boats holding up fine.