This weekend we were able to get some more done on the tear. The walls are now insulated and the door blanks have been cut out. The Insulation was done in a day. No big mystery here, just cut panels to shape and stick in place with a bit of glue. For the doors, the first plan was to make solid doors out of 3/4″ plywood skinned on both sides to match the interior and exterior finishes.

Plan “A” fell through once we got a look at the big box store plywood. After checking two different stores, we gave up on finding decent, flat plywood. On to plan “B”.

Plan “B” was to make a frame for the door out of 3/4″ lumber and skin that. After digging through about a hundred boards, we found six that would work. So we brought them home (along with some contact cement for the insulation).

Later the same day, I made a run to C&O Lumber and guess what I found… That’s right, stacks of nice FLAT 3/4″ plywood. So it’s back to plan “A” (or is it plan “C” now?). A bit of planing and a bit of cutting, and I now have two doors for the tear. There is still a bit of work skinning the doors and getting the sealing surfaces routed out, but all in all, a good day.

Thats another small step done. The 120V electrical is done and the 12V is as complete as I can make it without the battery and charger. Everything checks out ok and the best thing … NO SMOKE! Inside the cabin, there are three 12 volt outlets (one in the headboard and two in the upper cabinet) and two 120V outlets (one in the headboard and one in the upper cabinet). In addition, there are two reading lights and an overhead light inside. In the galley, I have one outlet of each type plus an overhead light. The 12V fuse “panel” and 120V breaker box are also located in the galley so I can troubleshoot it if necessary. The next big step will be the insulation.

I also need to decide what tail lights I am going to use. I have a square set that will mount low on the trailer or an oval set that can mount higher in the hatch. If I use the oval set, I will need to run some more wires into the hatch area before I get the insulation in the way.

Update: After a quick sketch, I can tell that I am going to go with the oval lights, they just look better to me.

It is getting closer, but there is still quite a bit on the ToDo list.