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Old 05-15-2016, 06:36 PM   #57
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stage 2

Next I used whatever was lying around to locate the aluminum where I wanted it on the frame rails and pinned it down with one 1/8" cleco in each outrigger.

Now just roll the sides up to the channel and secure then pull the remaining metal tight and temporarily secure to the channel.

I've left the plastic protection on and a bit of masking tape but I think after a trim it's going to look great.

I was worried that it just wouldn't work well on a deep frame but the front was a cake walk compared to the rear.

Next weekend I'll pop the side sections on and maybe a trim piece at the front and rear then it'll be time for the removable centre sections to be made up.
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Old 05-15-2016, 09:55 PM   #58
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Wow, that looks really nice!
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Old 05-16-2016, 07:05 PM   #59
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I think you can quit your day job now
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Old 05-28-2016, 09:31 PM   #60
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Slow progress

I got the oversize front hold down in place and final installed the aft belly pan curved sections. It went pretty well and sits really flat with 3M tape and 3/16" pop rivets.

I'm questioning whether I want to fabricate the aft centre section that wraps up from the belly to shell. As my chassis has a 6" x 2" tube crossmember there adding aluminum belly pan skin is really doing nothing but potentially trapping moisture. I whipped up a filler strip instead to see how it would function. Ultimately I thing the floor is well protected at that point but I can always revisit the pan there when I replace the outside body sections.

Pic of 142 linear feet of .032" T3 2024 Alclad boxed up. That's all the exterior save the compound segments. My trailer has multiple sheets joined together as it's quite long but I'm switching it out for longer sheets, 22', for a smoother leak free look.
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Old 05-29-2016, 09:56 AM   #61
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I think the filler looks fine, are you going to paint the that portion of frame silver or ????
I hope you have plenty of help hanging those long side sheets.
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Old 05-29-2016, 10:27 AM   #62
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Thanks Kip. A little reassurance goes along way. Yup I'm going to stick with the POR15 metal cloak silver or whatever they call their especially hard to apply speciality coating. I'm thinking I'll derivet the entire shell just holding in place with pops and cleco's they one by one template the new 22' skins then start replacement at the roof and work down to avoid "accidental" scratches. I wish I could have got some 040" on a coil but 5000' was a bit much
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Old 05-29-2016, 10:40 AM   #63
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Is .040 available from Airparts like the .032?
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Old 05-29-2016, 10:45 AM   #64
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Unfortunately not. The max on on coil
Is .032". 040" tops out at 4' x 12' from just about everywhere including airports. I will say they are phenomenal to deal with though they palletized and freight shipped all the way to Saskatoon for less than $200 and I even saved 5% tax as it crossed the border in another province which was another $150 saved or so. I'm secretly hoping that if I use professionally applied spray foam that the skins will look smooth
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Old 05-29-2016, 11:19 AM   #65
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Old 05-29-2016, 05:08 PM   #66
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Perimeter BP all done. The 3M tape is a real help and I added filament tape to the C channel BP contact points ready for shell time :-)
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Old 06-15-2016, 06:53 PM   #67
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Weather

It was insanely windy overnight; kinda glad I tied the shell down to the gantries. It's hard to see but the tail was pushed in and the whole shell moved, still no harm done. I decided to get started on the end caps by giving them a quick clean up (about 5hrs). I need them to be prepped so that when I take them apart to run through the English wheel I don't get any surprises....other than a million dents :-(

I used one 1/2 lb of Nuvite F7. It's my 1st time using Nuvite and I quite like it. It seems to produce a more consistent result than the Jestco system that I have used before. I'm going to try G6 next on the front cap and see what I like best. It's weird but I like the original look that the F7 left, it's got texture and character.
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Old 06-20-2016, 11:00 PM   #68
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The longest day

There was a bit of shell wrangling required but we got it all tied down. I'm pretty happy with how it turned out, everything fits really tight and just needs to be snugged down more before bolting at the hold downs. Really the only negative is the taper on the belly pan at the front. I think it would be better if it started at the seam, next time maybe :-)

Anyhow here's the pics with the new axle location.
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Old 06-21-2016, 08:03 AM   #69
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I agree about the taper, but water under the bridge now. Are you still planning to change the two piece side skins to one piece side skins?
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Old 06-21-2016, 09:01 AM   #70
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I am. I've got the sheet in 5 x 22' and 1 x 32' lengths. I just need the time to drill off the existing panels and template them up. I was planning to do the top (roof) centre strip first and work my way down. (I'm replacing all the skins with one piece copies instead of the current two piece sheet). I might even cut the window opening later but I might think about that a bit more.

Well, I also need to take down the gantries and reconfigure them or get some scaffold as I'm not climbing on the shell whilst it's only held in place at the hold down points on the bows. The extra trailer length does make some activities just that little bit harder.
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