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TaskCompletedNotes
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Minor Parts PrepNov 26, 2014
4
Assemble water intake hose
Oct 2, 2014
5
Make 120V circuit breaker box
Oct 27, 2014
6
Make 12V grounding block
Nov 2, 2014
7
Assemble drain pipe pieces
Nov 9, 2014
8
Finish wooden door and drawer pulls
Nov 5, 2014
9
Make cutting board
Nov 26, 2014
Make to fit on sink surround
10
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Material PrepDec 16, 2014
12
Rip spars to width
Nov 15, 2014
Tape together in groups of 6 and in complete block to minimize warping
13
Rip bottom plates to width
Nov 15, 2014
Tape together to minimize warping
14
Join template plywood
Nov 16, 2014
Use weight to clamp
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Join outer wall plywood
Nov 23, 2014
Use #5 screws to clamp
16
Join floor plywood
Nov 23, 2014
Use #5 screws to clamp
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Glue nut / washer combos for bottom plates
Nov 28, 2014
18
Join inner wall plywood
Nov 30, 2014
Tape inner seam to minimize overflow, use board stacks and weights to clamp
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Lay out profile and door on template
Dec 7, 2014
For door, lay out door hole, outer skin, inner skin
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Cut out template profile
Dec 10, 2014
Cut large, sand to line
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Cut out template door hole
Dec 14, 2014
Cut large, sand to line
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Cut out template door
Dec 14, 2014
Use outer line, cut large, sand to line
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Mark spars on template
Dec 16, 2014
Check measure roof fan and skylight
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Install FloorJan 7, 2015
26
Wash and prepare trailer frame
Dec 30, 2014
Remove fenders and unhook wiring
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Cut floor to size
Dec 30, 2014
28
Drill trailer frame
Dec 31, 2014
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Shape bottom plate
Jan 1, 2015
30
Finish floor bottom with roofing tar
Jan 2, 2015
2 coats, allow to dry completely
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Place floor and dry fit bottom plate
Jan 2, 2015
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Epoxy nut assembly to bottom plate
Jan 2, 2015
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Drill floor and bottom plate for bolts and T-nuts
Jan 3, 2015
34
Sand floor top
Jan 3, 2015
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Install T-nuts and floor bolts
Jan 4, 2015
36
Finish floor top
Jan 7, 2015
3 coats floor-grade polyurethane, leave T-nuts exposed
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Install WallsJan 27, 2015
39
Sand exterior plywood joints
Dec 26, 2014
Fill screw holes / seams with Bondo
40
Shape exterior walls and door holes
Dec 27, 2014
Careful of seam orientation, use router with flush trim bit and guide template
41
Cut out spar slots on template
Dec 27, 2014
42
Cut out exterior doors
Dec 28, 2014
Use router with flush trim bit and guide template
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Mark spars on exterior walls
Dec 28, 2014
Trace spar slots on inside, mark drill holes on outside
44
Shape interior walls and door holes
Dec 28, 2014
Careful of orientation, use router with flush trim bit and guide template, cut spar slots in process
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Trim template door to inner wall line
Jan 1, 2015
46
Cut out interior doors
Jan 1, 2015
Use router with flush trim bit and guide template
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Install bottom plates on exterior walls
Jan 8, 2015
48
Install interior door surround
Jan 10, 2015
Use template as guide, trim to width allowable by mounting method
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Install interior hatch surround
Jan 13, 2015
Use template as guide, trim to width allowable by mounting method
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Install wall foam core
Jan 17, 2015
Cut tight to fit, glue all sides, trim to marked spar slots
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Glue double spars
Jan 24, 2015
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Cut spars to length
Jan 24, 2015
53
Install interior wall skins
Jan 24, 2015
Rough sand edges
54
Finish interior walls
Jan 26, 2015
3 coats floor-grade polyurethane
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Finish exterior wall bottom with roofing tar
Jan 26, 2015
2 coats, allow to dry completely
56
Install wall assembly
Jan 27, 2015
Prop with minimal spars, all spars to be installed later
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Build / Install GalleyMar 23, 2015
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Cut all galley pieces
Feb 20, 2015
Use real dimensions of finished walls, watching for curving and wall thickness changes
60
Dry fit all galley pieces
Feb 20, 2015
Test fit appliances and gear, add organizers as needed
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Cut holes for sink and tap
Feb 20, 2015
Test fit sink and tap
62
Disassemble
Feb 22, 2015
Make sure orientation is clear
63
Cut holes for electrical
Feb 22, 2015
64
Finish all exposed surfaces
Mar 7, 2015
65
Install knobs and catches
Mar 22, 2015
Adjust cabinet doors, install bumper pads
66
Install all members
Mar 23, 2015
Install awkward electrical fittings while raceway open
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Install Electrical SystemMar 28, 2015
69
Dry fit shore power input
Mar 7, 2015
70
Install 120V electrical plugs
Mar 11, 2015
71
Install 120V wiring
Mar 11, 2015
Support and control tension
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Test 120V system
Mar 11, 2015
73
Install 12V components
Mar 21, 2015
Items over cabin: dry fit only
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Install 12V wiring
Mar 26, 2015
Support and control tension, keep uniform offset to spars and sides and as-built before covering
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Test 12V system
Mar 28, 2015
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Install Inner Roof SkinMay 2, 2015
78
Dry fit orthogonal template plywood
Jan 28, 2015
Loosen base bolts, use sheets for future galley construction
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Dry fit all support spars
Feb 7, 2015
Ensure countersinking is deep enough for filling and sanding
80
Dry fit roof fan and skylight
Feb 7, 2015
81
Cut and join headliner
Mar 7, 2015
82
Install headliner and spars
Mar 8, 2015
Remove and glue spars one by one
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Cut headliner to accomodate roof fan and skylight
Mar 21, 2015
Flush trim with router, make holes for lights
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Finish headliner
Mar 27, 2015
Prime, then paint with 3 coats mildew-resistant paint
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Install edging and trim
May 2, 2015
Trim to hide headliner join at top and bottom, side edging to mask gaps
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Install Outer Roof SkinMay 3, 2015
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Install roof foam core
Apr 3, 2015
Cut tight to fit, glue all sides, leave gaps for electrical
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Install exterior roof skin
Apr 18, 2015
Tack to spars, glue to spars and insulation, watch for electrical
90
Fill nail holes, gaps, and depressions
May 3, 2015
Leave fine finishing work for exterior finishing
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Build DoorsOct 4, 2015
93
Cut interior window holes
May 17, 2015
Modify and use template
94
Cut exterior window holes
May 30, 2015
Use template, offset from edges
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Dry fit exterior panels and remove
May 30, 2015
Adjust size and hinges as necessary
96
Install door body interior surround
Jun 14, 2015
Clamp to template, build and glue layers, trim, remove
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Install interior latch
Jun 14, 2015
98
Install latch handle surround
Jun 21, 2015
99
Install foam core
Jul 12, 2015
Cut tight to fit, glue all sides, leave gaps for electrical
100
Install interior skin
Jul 26, 2015