Roof Beam Installation

I have given up with the weather forecast.  I am just going to look out the window in the morning and decide. :-)

I got out this morning nice and sharp (8.30).  The first job was to make the jigs I need to install the roof beams.  These had to do 2 jobs.  Make a straight edge to pull the top of the side sheet true.  This is what they looked like before.

Its all wonky

They also needed to support the beams prior to welding.

I had a couple of hours before the gym which was just enough time to make them and hook them on.

The block sets the right height

All clamped, straight & true

Once back from the gym the I got started again.  The following time-lapes movie tells the story.

Roof beam installation movie (Divx HQ might take a while to buffer)
Same movie but Youtube stream (Lower quality)

I have edited it down a bit to show the general process.  What is not shown is the (boring) time spent truing up the sides.  Using a sliding bevel as a gauge on the outside and 5 ratchet straps inside I pulled the sides in true to each other.  This involved over flexing steel until both sides lean in at the same angle which is set by the rear bulkhead.  Not difficult, just time consuming to get it right when there is no tension on from the straps. This is why I only welded the top of the box section.  I will weld the verticals once the roof is on just in case things move again.  This will lock it all solid.

You will see on the video how the jig slides up ready to set the next set of beams.  I have to say I am rather pleased with my design on that.

Another half day hard graft.

The weather was eventually kind late on in the morning.  By lunch time we had the remainder of the port sides on.

 

After  lunch it was time to cut the roof beams.  Frank had a spare afternoon which was handy. With his help I made a template roof beam then we set about cutting all but 5 of the beams.  The remaining 5 will need to be cut as the front of the boat narrows slightly.

Its amazing just how much easier it was with 2 people.  I am so used to working on my own.  For sure 2 people working in sync can be more than doubly effective than 1.  Plus each of the 25 roof beams weigh in at 25kg and each needed moving at least 4 times including lifting then into the boat ready for installation.  To say I'm a little achy after a couple of days of construction would be polite.  Knackered would be a better description! 

A day of 2 projects

Today was going to be a motorhome build day.  I started out working in there setting up the shower area, and things were going nicely.  About midday I came in for a coffee and decided to follow up on a message I had left for a chap I know with a mini digger that hadn't got back to me.  When I got through I explained that I had left a message asking if he could come over at some point and consider using his mini digger as a crane to get the side sheets on the boat.  He said he hadn't had the message but was passing by in a short while and would call in.

Shortly after, he duly arrived and said "no problem when did I want to do it"? I said "today would have been just great as there was no damp or wind".  "OK then" he said my digger is just across the road I'll bring it over just after 1 o'clock. He has a stone crushing site just up the main road from me.

I needed to get the front starboard side on as per the previous post.  Frank very kindly helped me man handle this into place so I could attach it ready for his return.

Within minutes of him arriving with the digger we were ready to go.  I had pre-drilled the sheets so shackles could be put in for the lifting.  Initially these were found to be too far apart as the sheet bent too much.  A couple of additional holes nearer the centre of the sheets and we were in business.

Frank the digger

Second section being manoeuvred.  It's tight this side!

A good tack weld every foot or so to align and hold in place

Frank even got inside to help with the alignment

A couple of hours later and the side was on

It was great working with Frank.  Its nice to work with someone that just knows what to do without having to be told, it certainly speeded up the job. We even managed to get the second part on the port side done before the light went.  

In anticipation of the weather playing ball tomorrow he has left the mini digger on site for an early start.  The forecast is for 20% chance of rain, but that was the same as today, so fingers crossed.

Slightly blurred taken without flash in low light

Yipee!

After what seems for ever I have finally got on with what looks like some construction.  I have of course welded the rubbing strakes on, but that is not the same as sticking big bits on.

After a very frosty start the first task was getting the frozen sheets apart.  It was surprisingly difficult.  Sure they weighed in at 78kg each so this its self needed manually lifting to seperate, but to break the frost grip was a harder job than I would have put money on.  Once apart the ice grip pattern was only about 2sq/f.  I think if the whole sheet was frozen it would have been impossible.

The template I had cut from vinyl before Christmas came out along with the hard board practice piece.  I had to modify the shaped front end a little and amend the template.

 
Previous blog entry

Once the steel was cut it was time to get it in place.  (Bear in mind here I have a dodgy knee at the moment).  The cut piece now weighed 64kg.  With a bit of a struggle I managed to walk it up the stairs, then carefully I laid it on the gunwale and I was delighted it fitted perfectly.  A bit of a tap with a club hammer to get it in the right place at the front, then tack welding to get it to follow the curve of the front of the cabin.

I have decided to tack the whole job up then go back and weld it once everything is in place.

First cabin part in place :-)

On a side note.  The aluminium steps you see I bought at an auction about 7 years ago for £20!!!  At the time I had no use for them but for £20 it would have been mad not to.  The safety rails are easily lifted out.  They are going to be perfect for working on the outside of the boat.

Steel Order Arrived

The steel to complete the shell sides roof and water tank arrived today.

Now all I need is some good weather a mini-digger to lift the sheets, oh and my knee to ease up so I can get on with construction.  I went skiing last week and once again knackered my knee.  Its become an annual event over the last few years, so I have made an appointment to see a knee specialist.  I did the original injury 20 odd years ago skiing.  I'll never learn  SWIMBO says.

Many thanks to my friend Andrew for attending with his all-terrain forklift to unload the steel. It doesn't look much for £2k but there is about 2 tons all cut to size and some profile cutting.

I have the parts for the skeg as well as a couple of bits of steel I didn't order.  I need to find out how the skeg goes together, although I shan't be needing that any time soon.

Snow Boat

Christmas & the weather has kind of put pay to play.

I am now waiting on the steel I ordered just before Christmas to be delivered.  Normally I would have waited until after Christmas to order the steel, but as there was quite a few £'s worth I wanted to save on the VAT increase.  Also I know from my day in the trailer business, the steel wholesale business is not the hottest in December so I was able to hammer out a good deal for the remainder I need to build the cabin sides and roof.

Snow boat

Steel Is Ordered

I have now ordered all the steel to finish the sides and roof as well as making an integral water tank.  This should be with me in the next couple of weeks.