Getting ready to take the roof off, first unhook the canvas out of the upper track on the roof. Take down the curtains too.....
Wire entrance into the roof, these wires power the marker lights and ceiling light. I will be adding more ceiling lights. You will have to cut the wires to remove the roof.
The canvas may be held in by a screw on each end over the bunk. This prevents it from coming out as you crank the trailer up and down.
Remove the bolts for the lift arms. If they just spin, you can pull the lower track, and remove the outside aluminum to access the T-nut and hold it, or cut the head off the bolt.
Really sagging here.
To remove the door- find the screw in the hinge (it sits in the slot you can see) and slide the door back and forth to remove the screws. If you don't take the hinge apart life will be much easier.
Son helping remove the lower gasket.
Rot
Had to pull this side all off just to get the bolts for the lift arms out.
Humpty Dumpy .........
Cutting the sides. The front and back sides are 77-5/8"X7".
Copying the side. I later used a thin batten to redraw the curve on the passenger and driver sides. the sides are 7" at each end and 7-7/8" in the middle. The end of the 8ft piece of plywood is 7-3/16" . I also added 2" in total height.
Too rough to use. But I tried.
laying the pieces up. Glued and screwed together. The small pieces are on opposite ends.
The sides with the interior frame in. I used 1x2 pine for the frame.
Squared it up
Side brace where the small piece of plywood is, I moved it to the interior to finish the outside
The 2 sheets of plywood (1/4") on the exterior of the roof. The plywood was cut to 78-7/8" and checked for square. The plywood was glued and stapled to the frame. I pried the center up to stress the roof some.
Hot out, but I got in for a swim after this.
The pry is just visible that I put in to try to stress the roof in place.
The side was full of holes.
Used the screw to pull the side out to get it square.
The top all covered. Filled the cracks an mistakes, as I will be putting polyester resin and fiberglass on it.
The numbers
Blocks of wood in place for the lights and the door locks (for when the the door is locked to the roof) Glued down. I added another cross brace after this to stiffen the panels.
Adding insulation. This will be glued down as well after wiring.
Rain Break
The t-nuts that attach the roof to lift arms are visible. I used a 5/8 forstner bit to counter sink them flush. You don't need to do this if your reusing your metal. The t-nuts are 5-1/4 from the bottom, and from the ends (4 corners the same)
Wiring
Wiring, The wiring is soldered at each joint. Reliablity will be built in.
My daughter learning to solder. A great open area to learn. Hey, look Dad I did it.........
The project
Had to drag the hand plane out to smooth out the inner plywood edges
Adding interior trim wood same 1/4" as the exterior skin
Putting the trim in
Adding spots of building adhesive along the back of the trim
littl" helper
Meaasure twice...........
(CLIP) adding trim across the interior joints
Dry fit of aluminum bottom trim
Had to clean all this gunk out of the bottom trim to get a proper fit. Used a utility knife and chisel.
Starting to glass, What A Mess I made......
Primer on the interior woodwork
New glass for the roof. I had to remove the original pieces as they were ruined as I started it when it was too warm outside
I like epoxy, not polyester. This stuff is nasty but it works. Double glove and try to keep the stuff off you. The container is marked with resin and hardener levels, the resin was measured and poured into another container before mixing.
The garbage pile, ick
Sealed up.
Painted with oil base primer and Acrylic topcoat.
Set in place, I tied rags over the top of the upright lifters to protect the interior paint.
Crank it up to hook the canvas on.
Putting the screws that hold the canvas in the track back.
Battening up the sides.
I used a short wide screwdriver to push the canvas down into the lower goove. Then pushed the top in. It helps to have a helper hold the loose side of the canvas up.
