Rug-ed

Much has happened since my last post.  However, almost all of what has happened does not involve the jPod.  The life of a teacher has overcome me like an ocean wave and I haven’t been able to work on the jPod.

Senior Management has done some work on it though.  She filled all of the staple holes in the roof and found a carpet remnant that we’ll use as the headliner inside the cabin (see Body:Internal).  It looks nice and will go with her color scheme for the inside of the cabin.

At some point I hope to be able to get a bit more work done on the jPod (even just as a stress reliever from work).

Skinned

Since my career has picked up again with the start of a new school year, most of my time has been devoted to preparing to teach my classes again.  I have also received a shot to help me with my allergies which is mildly helpful (at least it makes it less likely that I’ll suffocate).  In the middle of all of this change, Senior Management and I made some time to skin the jPod’s outside roof.

Router in insulation makes for a mess

We decided to run the 12v battery line through a 12 gauge extension cord.  It is really burly and replaces our previous plan of conduit with smaller gauge wire running through it.  Instead of carving out little channels in our insulation for the wiring, I chose to run the router through it with a straight bit.  It worked well but made quite a mess (see updated photos on Body:Internal).

We skinned the jPod and attached the skin with glue and staples.  We drove screws through the skin into the spars to hold the skin down while the glue dried.  Then senior Management removed all of the screws.  I trimmed the sides and it was done (see updated photos on Body: External).

Our next step is to prepare the doors and hatch for epoxy so that we can epoxy the roof, doors, and hatch at the same time.

Senior Management and I also made a change to our plans for the galley.  Nathan and I figured out the amount of electricity needed to use a convection toaster oven.  It is too much electricity for comfort.  So, Senior Management and I purchased a Camp Chef Outdoor Camp Oven.  It runs on propane and is an oven + burners.  You can read more about it here.

Rated R

Yesterday, I wired the cabin of the jPod.  Then Nathan (a good friend and faithful reader of this blog) and I insulated it with 1″ insulation.  The R values of the insulation dropped the temperature in the cabin considerably.

In our discussion, we determined the best physical places for various electrical components.  I am going to run a 12 gauge extension cord from the electrical panel in the cabin over the roof to the battery on the tongue box.  This will be strong enough to last a very long time and will not require conduit.  I also chose to put the cabin wiring in a separate line on the roof for the sake of space.

Separate Wiring for 12 lighting

I have received my harsh environment living hinge from McMasters.  I am quite impressed with it.  It will hold 100 lbs. per square inch and supposedly is next to impossible to damage.  I will use this hinge on the two side doors.

Senior Management skinned the side doors yesterday.  They look great and she did an awesome job.

Today, is my last day as a teacher on vacation.  I am going to try to get some more work done on the jPod before tomorrow.  After that, it may be a while before I can work on it more.

Workin’ in the Shade

A lot has happened in the past few days.  I have spent some time working on the jPod.  Senior Management and I have also had to deal with some aspects of reality in life as well (all of which are distracting from the build).  The good news is that the internal roof skin is now installed.

Skinned just before it got dark

I have read about the process to put the skin in but haven’t been able to find photos on the Internet so Senior Management shot photos while I prepped the skin for installation.  It was fairly easy.  On our first try, the skin was just enough too wide that there was too much friction to move it into position.  With all of the attempts to push it into place, I cracked one of the pieces of skin.  So out it came and I glued it up again.

The real way to put the skin in is with boiling water.  You can read more about this process on Body:Internal.

Today, I plan to do some spot checks on the internal skin to make sure everything is tight.  Then I’ll run the router through the vent hole in the ceiling and along the back where the galley hinge will be.  Next will be wiring and insulation.  I think I am pretty pleased with my wiring diagram on Body:Internal and plan to stick pretty close to that design.

Since my last post was a while ago, I have shot many new photos (about 60).  I have put some of the better ones (for illustration purpose not quality photography) on Body:External & Body: Internal.

With the roof in, soon I’ll be workin’ in the shade!

Son of a Biscuit

One of my fears became a reality today.  I fear making a major mistake that requires the entire US gov. to help cover up.

Today was somewhat productive.  I managed to work on the jPod between yard-work and other duties.    I did some follow-up sealing work underneath the trailer where the walls attach to the floor. I also got the inside of one wall wired up and skinned.

Drilled a 5/8" hole too low. Now what?!?!?!?

Right at the end of the day, I decided to cut the newly skinned inside for the doorways, electrical access, and windows.  I pulled out the router and cut away.  The “oh-poop” moment struck when I drilled a pilot hole for the router that should have been in the electrical access point on the galley bulkhead.  I was confused by some of my pencil marks on the wall and drilled it too low.  SON OF A BISCUIT!  Of course by this point, my polyurethane adhesive was pretty much dried and nothing would pull the skin off of the inside unless it was a good fire.

So I have a 5/8 hole to work with.  I don’t want to patch it because that will show through a natural finish.  I need to find a creative way to work with the hole.  Apparently, my brain hates me and thinks that the challenge of building a tear for the first time isn’t quite enough problem solving.  Oh well.

I have updated my Body:External page with new photos & Body: Internal with the pictures of the new skin.

In a more joyful mood, I ordered the hinges for the cabin doors.  I decided to go with McMaster’s Harsh Environment Living Hinge.  It is a UV resistant plastic hinge that can hold 100lbs per square inch.  It should be durable and will be easier to seal up than a conventional piano hinge.  Plus, it should be pretty quiet.  I’ll add McMasters to my Material Supplier page when I receive the hinges.