|Posted: Wed Sep 12, 2007 7:44 pm Post subject: Fitting cabin top
I'm now to the point of fitting the fiberglass top to the fuse. Like
most of us with minimal fiberglass experience, I approached the fitting
with some trepidation. I wanted to pass along a way to help get
started. I did the rough cutting to within 1/16 th to 1/8 th of the
line around the doorsill. I then got some help and tried to muscle it
into place. After about two tries it became quickly obvious that about
1/4 inch needed to come off from the width of the door. The fiberglass
had to be trimmed just about to the curve on each side. It also becomes
obvious that the first place it must fit is between the door jambs.
Rather than take the top on and off with each bit of sanding, I thought
the best way might be to make a door sill template. Overall, I think it
speeded up the process as it "only " took 4 tries to get the top to
start fitting inside the sills.
To make the template, first of all don't try to measure anything.
Reverse engineer it. Take a 3/4 inch piece of plywood or MDF ( slightly
larger than the opening which is about 37 x 12 inches) and get (3) 12
inch x 2 inch boards.
Take one board and use a single screw along the base. This will support
the backer board along the sill. Now take another one of the 12 inch
boards and screw it vertically so it can be clamped to the back
upright. Make sure it is above the small flange in the corner. Now put
the third board up against the front upright and mark it's position
(outline ). Remove the boards and screw the front upright in place.
Now you have the width and size of the opening.
Take 3 more 2 inch wide boards. One about 40 inches long and two more
12 inches. Use the long one as the base and use the uprights from the
template to hold the vertical 12 inch boards. Screw them into the base
of the 40 inch board and then add some scrap triangles in the corner to
hold them square.
You now have a template that you can fit over the fiberglass while you
are sanding/trimming. Once the template will slide over the fiberglass
top it will fit between the door jambs and you can then see how the
joggle fits and needs to be trimmed and see how you need to radius the
I'll put some pics on my site at mykitlog.com in the next few days. I
just realized my access to the site was down. If anybody is about to
fit their top and needs pics I'll send them to you. Too many and too
large for the list.
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