1 001-The wheel house without the roof on.jpg
2 002-another angle.jpg
3 003-the funnel lieing on the roof.jpg
4 004-and another angle.jpg
5 005-the roof not fouling the hatch.jpg
6 01-the old roof.JPG
7 02-the other side.JPG
8 03a-cornerdetail.JPG
9 03b-how much does it weigh.JPG
10 03c-27 kilograms!.JPG
11 04-joint detail.JPG
12 05-delaminated beam.JPG
13 06-the old fasterner.JPG
14 07-that looks good!.JPG
15 08-workbench-before we started.JPG
16 09-other junk in the work room.JPG
17 10-and some more-what a mess.JPG
18 11-back to work.JPG
19 12-planning the curve to shape.JPG
20 13-Cadcam drawn fullscale plan.JPG
21 14-all the same.JPG
22 15-marking side rails.JPG
23 16-and again.JPG
24 17-load test a beam.JPG
25 18-cutting sderail joints.JPG
26 19-dryfitt.JPG
27 20-mixing the glue.JPG
28 21-appling glue.JPG
29 22-appliing glue.JPG
30 23-clamping block-wraped in clim film.JPG
31 24-cheaking the size.JPG
32 25-all clamped up and curing.JPG
33 26-Testing diffrent roughing shapes.JPG
34 27-a didffrent one.JPG
35 28-a little 5th scale mockup.JPG
36 29-a little 5th scale mockup.JPG
37 30-profiling the top of the side rails to the curve.JPG
38 31-and the other side.JPG
39 32-the new frame against the old roof.JPG
40 33-yeah, there good enough.JPG
41 34-wookroom again-looking more worked in.JPG
42 35-Drip edges cut and glued.JPG
43 36-Varous parts and off cuts at school.JPG
44 37-Planing the Drip edges.JPG
45 38-The rest of the ply coming home.JPG
46 39-The ply by the roof.JPG
47 40-Roughting the underneath edge of the ribs.JPG
48 41-The ply-yes that was a 10x5 ft sheet!.JPG
49 44-Cutting the ply to size.JPG
50 45-The and that sands.JPG
51 46-The hand the sands curves.JPG
52 47-The hand that sands sheets.JPG
53 48-Planing the top of the side drip edge.JPG
54 49-The clamping 'bed'.JPG
55 50-marking the centres, so it gets glued stright.JPG
56 51-The Centre Mark.JPG
57 52-All clamped up, (dryrun).JPG
58 53-The clamps again.JPG
59 54a-Pumping out some epoxy.JPG
60 54b-Mixing up epoxy for glueing the frame to the ply.JPG
61 55-Spreading the glue on the frame.JPG
62 56-more glue spreading.JPG
63 57-No photo during position, clamping, sorry!.JPG
64 58-All clamped up in the right places.JPG
65 59-scraping of excess.JPG
66 60-cleaning it up more.JPG
67 61-Leave it!!.JPG
68 62-WOW, just out of the clamps, how cool does that look!.JPG
69 63-Old roof New roof.JPG
70 64-Still looks like a sheet of ply tho.JPG
71 65-Roof has been weighted at about 14.8kg so far.JPG
72 66-Dry run clamping side edge.JPG
73 67-1st edge peice on, cleaning up.JPG
74 68-cleaning up again.JPG
75 69-as you can see tempurature was carefully monitered as much below 15C cureing is VERY slow.JPG
76 70-the 1st aged on, planing the over handing ply .JPG
77 71-2nd side edge on.JPG
78 72-the first end going on.JPG
79 73-the 4th and final egde on and clamped .JPG
80 74-planing of that overhanging ply.JPG
81 75-vutting the side edges to lenght.JPG
82 76-planing the ends.JPG
83 77-as you can see, the laft 100mmof the ply runs stright, because the frame is nowlong holding it curved.JPG
84 78-Sanding sanding sanding, about two hours of sand epoxy!.JPG
85 79-phew, all done.JPG
86 80-mixing up the epoxy for filleting (the lowdensity addative is a lovly brown shade!.JPG
87 81-piping on the fillet.JPG
88 82-smoothing out the filltet.JPG
89 83-and scraping of the excess.JPG
90 84-there, one fillet all the way round.JPG
91 85-and up the corners.JPG
92 86-more filleting, only not with lowdensity filler.JPG
93 87-filleting between the side rails and the frame.JPG
94 88-the two fillets side-by-side.JPG
95 89-again, time to LEAVE it.JPG
96 90-sanding the fillets down to smooth.JPG
97 91-the fillets all sanded.JPG
98 92-planing the upstands, that will go along the front and back edges.JPG
99 93-radiusing the edges for the roof ready for sheathing.JPG
100 94-Sticking the upstand on.JPG
101 95-Both upstands on.JPG
102 96-planing down the upstands.JPG
103 97-cornerdetail.JPG
104 y01- We're going to use the garden table as a stand.JPG
105 y02-ready to go.JPG
106 y03-glass cloth cut and layed out ready.JPG
107 y04-Using wet method for this edge.JPG
108 y05-laying down the strip.JPG
109 y06-as you can, with the epox on it does almost clear.JPG
110 y07-butting up the next sheet.JPG
111 y08-all the rest was done using the dry method, and the large sheet hold itsself in place better.JPG
112 y09-wetting though the sheet.JPG
113 y10-and the edge, etc.JPG
114 y11-Including under that edge.JPG
115 y12-the cloth will be trimed flush once it is semi-cured.JPG
116 y13-halfway done!.JPG
117 y14-butting up the second sheet.JPG
118 y15-just pour it on, it'll be fine!.JPG
119 y16-nearly done.JPG
120 y17-the cloth was tape up, we could do the under edge.JPG
121 y18-the center join, only butted up, to make it less visable.JPG
122 y19-all done, and curing as a speak.JPG
123 y19-one of the corners.JPG
124 y20-a small peice use to monter curing, and the therometer.JPG
125 y21-Once the epoxy was part-cured, the excess cloth was trimmed.JPG
126 y22-bit blured, but you can still see ply,edge, etc.JPG
127 y23-rollering one the white pigmented epoxy.JPG
128 y24-One coat of white all over.JPG
129 y25-my the time we started the 2nd coat it was gone 23.00! .JPG
130 y26-laying off tool.JPG
131 y27-on goes the second coat.JPG
132 y28-the rollers done last very long! atleast there cheap!.JPG
133 y29-2nd coat all finsihed, time for bed!.JPG
134 y30-clocks went forwards tonight as well, so effectly is 2in the morning now!.JPG
135 y31-rounding the rought edge of the grp with a file, ready to coat the underneath.JPG
136 y32-sanding the bottom edge, as the underside coat will overlap the top coat along this edge.JPG
137 y33-a mild chamfer was put on the outside of the rails to help to roof fit inside the cabin walls.JPG
138 y34-the roof aclimitising to the warmer temp.JPG
139 y35-on goes the first epoxy.JPG
140 y36-the epoxy is very thick, spreading it is very hard work.JPG
141 y37-nearly done the main areas.JPG
142 y37-starting on the edge.JPG
143 y38-then for the very edge some white was mixed in.JPG
144 y39-nearly two hours of hard spreading, the first coat is done.JPG
145 y40-3hours later, and its time to start all over again!.JPG
146 y41-all done for the second time, all thats left now is the fittings.JPG
147 y42- the roof was then washed in 50-50 mix of vinager and boiling water, to remove the exodadte off the epoxy.JPG
148 y43-washing the topside of the roof.JPG
149 y44-the underside was washed just with soapywater as the exudate was fresher.JPG
150 y45-you can see the exodate on the right of the test peice, and i left long with yellows more, hence removing it (left side).JPG
151 y56-the roof now wieghts about 20kg, so should finsh at about 22kg with the hand rails.JPG
152 y57-scales only weight upto 14kg, so the roof was weighed in two halves.JPG
153 y58-the new longer hand rails.JPG
154 y59-the old stands where first washed in nitric acid (left) and then buffed on a machine (right) and will now be laquered.JPG
155 y-60 buffing the brass pliers.JPG
156 y-61 all the brass piller, incuding the new end ones, the crome rail used is just for ilustration.JPG
157 z01-the roll of glass cloth, 135gsm, plainweave .JPG
158 z02-some test squares to test diffrent aplication techniques.JPG
159 z03-TEST1, drymethod grp sheath, pouring on epoxy.JPG
160 z04-TEST1, drymethod grp sheath,spreading on the epoxy.JPG
161 z05-TEST1, drymethod grp sheath,was the epoxy wets the cloth you can see it going clear!.JPG
162 z06-TEST2, wet method grp sheath,pouring o the intial epoxy.JPG
163 z07-TEST2, wet method grp sheath,sprading out the intail expoy.JPG
164 z08-TEST2, wet method grp sheath,laying the cloth over the wet epoxy.JPG
165 z09-TEST2, wet method grp sheath,pouring on the secondary epoxy.JPG
166 z10-TEST2, wet method grp sheath,sprading out the 2ndary eopxy.JPG
167 z11-TEST3, stright epoxy with white pigment.jpg
168 z12-TEST3, stright epoxy with white pigment, rollering ou the epoxy.JPG
169 z13-TEST1&2,the finished affect of the grp sheathing.JPG
170 z14-once the grp sheathing is cured i coverd it with a layer of pigmented epoxy.JPG
171 z15-pouring on the pigment epoxy.JPG
172 z16-rollering the white epoxy over the grp.JPG
173 z17-didnt mix quite enought to fully coat all the grp, but you get an idea of the finish.JPG
174 z18-this is the Epoxy only test with a 2nd coat over half of it.JPG
175 z19-weiging the test peices.JPG
176 z20-highdesity fillet sample.JPG
177 z21-lowdesity fillet sample.JPG
of 177
03c-27 kilograms!
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