Pro-Rig V2.0 - Home Built Compact Composite Pop-up

CoyoteThistle

Adventurer
Not much real progress other than fiddling around with the table. Next step was a scary one - routing out the pretty finish I've worked so long on for the hinges.

I made a funky but functional jig



It took longer to make the jig than to do the actual routing on the table, but the results were very consistent and just about perfect, whew! I did the deeper cut on the edge without a jig - nervous stuff but it all went well. Wound up with a eight cuts like this



And, once all routed, re-stained around the edges and sprayed with a couple layers of shellac, it looks like this



All I can say is it is likely the only honeycomb core, zebrawood veneer, dual leaf table in existence! :sombrero:

I'm gonna get a little OCD on the finish still (I've come this far, right?) before actually mounting the hinges.

Second pair of roof lifters arrived today, I'll hopefully have enough time to get them mounted up soon and test fit the slide-up...
 

ottsville

Observer
Wow! Beautiful work! Just found out carboncore is about 15 minutes from me...might have to find a reason to use some of their stuff.
 

CoyoteThistle

Adventurer
Thanks for all the kind comments everyone!

No updates to report on the electrics (sorry Anton) or anything else really. A little rain over the weekend killed yet another attempt at more painting :mad:.
Just ordered up some aluminum angle so I can (hopefully) get the roof lifters installed - had to do some re-design of the mounts and will need to do a little surgery on the medicine cabinet - I think I have a plan for it now...
 

guidolyons

Addicted to Gear Oil
All I can say is it is likely the only honeycomb core, zebrawood veneer, dual leaf table in existence! :sombrero:

I'm gonna get a little OCD on the finish still (I've come this far, right?) before actually mounting the hinges.

Second pair of roof lifters arrived today, I'll hopefully have enough time to get them mounted up soon and test fit the slide-up...


Very cool :sombrero:
 

CoyoteThistle

Adventurer
Thanks for the continuing positivity all!

Finally got back out for a very little bit of progress today. Cut a chunk out of the medicine cabinet to accommodate the extra lifter. Never a good sign when the sawz-all comes out :(



I think it will work okay. Will need to add some more aluminum trim to clean up the look.

Just committed to a 10-day trip in mid July - better get this thing done!

So, after lots of real-world distractions the last couple weeks, I'm looking forward to a big weekend of pro-rigging! Stay tuned...
 

CoyoteThistle

Adventurer
Pretty busy and pretty productive weekend, mostly centered around getting the slide-up lifters installed. End result is four lifters installed.

Here's the rear pair:



I bolted them in through the wall with some finder washers. Aluminum angle across the top and bottom to tie them together and give a better mounting surface at the top.



At the last minute I added added some extra aluminum angle to the center and ends at to the top to give a little more surface area to attach to the slide-up.

Here's the front pair in the up position.



It was neat to see them in the up position but it was a major pain to get them back down. A couple ratchet straps were involved :eek: I think I'll have enough lifting power now - maybe too much??
 

CoyoteThistle

Adventurer
Interior is 76" wide by 84" long. Floor is 74".

About 60" of headroom with the slide-up up. Lots of headroom with the pop-up up.

Headroom above the bed is about 24" with only the slide-up up. With the pop-up up, its a wedge from 24" to about 40" (final height here will depend on the angle of the pop-up).

Exterior is about 45" tall and 78" wide when in travel mode .
 

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