Bob the Builder

We are on the same page for a lot of this stuff, Doug. Lowe's has a stain blocker type flat white, with bonding agents mixed in that help it to bond with other paint, glue, etc. $29 a gallon and I probably won't use the whole thing even with two coats. Covers really good and is pretty thick to fill smaller imperfections. The jack knife sofa sits probably 8" out from the wall at the base of the seat back. I'm thinking of a shelf at that level to the wall for the full length to roll up the bedding lengthwise and stow it behind the seat back when up. Underneath has about 18" of height from the floor. Although the water tank sits for the first half at the foot leaving 36W+ x 24D x 18H, I'm considering perhaps two small carry-on style roller bags slid under the remaining space with a short rail at the back to roll over and simple cord style net across the front until I decide what to build in under there. We want to use this thing for a while before entirely done to see what suits our travel style. I have one of those hot knives, just haven't used it for anything yet and the ac is 15+ degrees tilt when trl is level. You know what they say, great minds think alike! (as long as I ignore "Bob" for the most part.) All I need is a whole lot more of your energy. Started on rebuilding the windows today. How far has anyone taken these apart. Have samples for the rubber seals coming but I think I'm deeper into them than that already. Just not sure where/when to put any sealant btwn plexiglass and frame etc?

I figure I should probably update my progress as it has been quite a while since posting. I have been staying busy on the project and checking in almost daily on the forum. Doug, your pace on the build puts me to shame. I do accomplish something every day though, and even if I can't say that I see a light at the end of the tunnel, I can see a light! I thought I had found some new windows for the sides, but they were for 1 1/2" walls so I'm now at the point of rebuilding mine. I'll go back and read all the posts about doing the windows and I do have where to get the rubber seals from before. The power center and refrigerator are in place although I still need to make the bottom mount face plate that will hold it from walking out, (the base frame slides under brackets at the back). I have pretty much finished up this week on the kitchen counter area except for the backsplash and some little items like trim, etc. Have mounted the jack knife sofa/(wife's bed), and much to my delight, it opens past the front mounted ac. "Bob" told me it would, but we know about "Bob's" eyesight and wandering mind! It's been quite a while since he engineered that part of the build. Ran a pressure test on the shore plumbing supply and all fittings except the water tank and 12 volt pump. I was sweating that one; "Bob" again! Pretty much buttoned up the hot water heater cabinet and installed the electrical panel for the water heater and 12 volt pump switch. I made the panel fold out with the plug in for the water heater on the back side and it also gives me access to the valves for the water heater/ hot/cold water supply. I am still amazed at the strength of the styrofoam and fiberglass laminates and I will super pumped if the weight of the build comes in anywhere close to my plans. Enough carrying on, just wanted to show some progress. I'll post a few pics. Let me know what you think, all input is useful.

I have an 82 Sunrader shell I'm working on and I just measured the bare dimensions this morning for the over cab area. I came up with a rv "full" size for the mattress off of a chart of rv size mattresses.. 53" by 75" is the full size mattress that best fills the area in mine. I don't know if the years, etc. would make yours different or how the bare walls vs finished might affect the area compared to yours.

Bathroom wall covering question for the group. Has anyone considered or heard off anyone gluing roll linoleum on the bathroom walls? Totally insane or what? It's waterproof, doesn't weigh very much considering how small the pieces will be for each wall. Remember I will be gluing it to the fiberglassed styrofoam so my bathroom is already pretty much waterproofed. Just wondering if anybody has done it, has thoughts about how to, or has seen it done. After all, they do accent walls and such with it.

Doug, I hope you haven't already name your sunrader like some of the folks on here. I think with the way you are going with all of the fancy appointmens, etc. we'll have to call it "The Sunrader Hilton!". Sure is going to look spiffy. Keep er up.

Well, I got the Great Stuff hd construction foam in and it does like they say. Only thing is they say you can leave a can on the gun as long as you shut it off, and start it again whenever. Almost didn't get the $54 gun going again after maybe four days. Ran the cleaner through it and managed to get it back to operating as it should, only I don't leave product in the gun anymore. Clean it after each use now, so I try to get several things ready before I fire it up. Got the styrofoam and plywood in the bunk glued down and it feels very solid. I'm trying to pick and choose what I work on in the colder weather as my garage stays about 50-55 degrees. I had gone through the many types and styles of camper tail light modules and decide I would make my own. Happy with how the first one turned out. Glued a plate on the inside with nuts JB welded to it and wired in a weatherpak connector so I can remove the light module from the outside only in the future. Now that the left side light is in, I will finish enclosing the shower walls which I have already constructed. Building the right side light module now and soon I will be able to mock up the counter and finish up the drain and venting behind it.

Not that I know anything about sewing, but my wife has been doing it all of her life. I agree with extech about the stitch length and also, try using a bigger needle and heavier thread for more strength. Not meant to criticize, I think it's neat that you are willing to tackle this part or your build. I'm lucky, I would let my wife do it.

Another update. Have been working in several different areas, jumping around while waiting on different parts, etc to arrive. Seems like everything I start can only go so far until I move something else forward. Started wiring the power center and decided I needed a workbench right there. Worked out well and I kept the pieces because I will use it again when I wire up the 12 volt stuff. The plumbing is just about done except for the supply lines from the tank, etc, because I am putting down the vinyl floor before I mount the water tank. I have the shower pan in and all the holes through the floor to the tanks. I used some Great Stuff sealing foam to level off the sleeper floor and I think it worked out real well. I ended up using a bare hacksaw blade to cut the foam off level after it cured and I have the foamular and the plywood trimmed and ready to glue down. (waiting on Great Stuff construction foam for that).

Yes, Doug, the side windows. My sleeper side windows and the big cabin side windows appear to be the same thickness inside the trim flanges when screwed together bare, 7/8". The inside aluminum flange is exactly 3/8" and my sleeper side windows, (still mounted and sealed) have a hair less than 3/8" showing. I've been testing with a piece of 1/2" foamular @ different spots, including the back window,( mounted yet with flange installed), and if I put any kind of paneling 1/8 minimum, should be tight and close to seating the middle frame. Not to belabor the point, just more info.

Looking good Doug! I'm still amazed at how much stuff you are getting done in a short amount of time. I finally filled in my front "pass thru" hole and am getting ready to lay down a 1" piece of pink on the bottom then a thin sheet of plywood. I'm going to explore the Great Stuff foam construction adhesive for the glue on this and the wall foam. What kind of space did you end up with on your windows? Just curious.

You go, Doug! Looking good. Can some of that energy and send it my way. At least you are doing the part I'm not ready for yet. That will give me a leg up when I get there. Still plumbing and such on mine.

dondiego, I have peened the knurled part around studs with a center punch in several positions along the length of the knurl, effectively creating an exaggerated "knurl" which worked successfully for me in several instances. Not too scientific but effective.

Looks absolutely terrific, now you can do mine! Seriously, it looks great. I'm thinking about how much cooler it would be in the summer for us cause "Bob " don't do cold. I'm doing the foil backed instead of the foamular, but I understand your need for the strength.

Doug, your interior layout is different than mine, and I believe some of your window sizes are different also. Don't know if different windows translates into different thickness. I measured again the existing wood still in the frames that haven't been removed yet and it is 1/2". To be sure, you have to find out for sure what your are, but just sayin'. On gluing the foamular together, I'm using Gorilla Glue heavy duty construction adhesive and if gluing an insert into the foamular, using Gorilla Glue itself. The Gorilla Glue expands in case there is voids created in the holes, the construction adhesive doesn't. A lot of testing on the net on what works best with this method of construction. I'll expand on the cloth and resin as I go along. You can see in the pics, how strong an open sided sample "box" is and that is one layer of 2.5oz cloth and epoxy inside and out. Imagine if it was a cabinet with a shelf or two and the back side foam also. I have sat upon that "box" many times with my feet up to demonstrate and I'm 185+/-.

Looking good, Doug. I'm sure that's how I will have to proceed on mine.