No doubt about it.....I need to get a bigger garage!

Over the recent holiday weekend, I was able to pick up the newly-painted trailer frame from Roger's place.  It looks great and so it was only fitting that wood would be next.  It was over to Greg's after a visit to the lumber yard to cut the wood to dimension and then home again to wait for Saturday.

Beau-teous!  Roger does great work!

A truck to haul the wood......thanks Merrill's!

So today was the big day which I have been planning for sometime now.  From now on, January 25th should be known as Floor Day!  Let the fun begin....!!

Let there be wood...current time:  10:30am.

Last weekend, Greg and I cut the wood ribs to match the frame tubing from 10' two-by-fours.  We also cut the floor sheeting to the exact dimensions necessary.  With the wood pre-cut it seemed that assembly would be a "simple" matter...but it still took all all day.

Doubling the rim frame...clamp it...

...drill it....

...glue it...

...assemble it and repeat. 

The photo above shows all the wood frame members laid out in preparation for the cutting in of the wheelwells.  All the measurements were triple-checked for accuracy including a trip over to storage to verify the wheelwell dimensions.

Street side half first...

...then the curbside half.

At this point the rim frame was drilled, glued and screwed to the floor halves.  This went quickly as positioning was easy - flush to the outside edge.  The next step involved careful fitting of the interior frame pieces so in the end the assembled floor can be removed from the trailer frame for waterproofing.

The sun kept moving...after 2pm it was cooling off quickly. No time for lunch.

Both sides aligned and ready for the drilling-gluing-fastening routine.

Adding the last 16" to the floor.

The floor is nearly finished...good thing 'cause so is the daylight!

Fitting the trailing edge frame piece came next followed by the leading edge plate.  This was offset forward to accommodate the angle cut at the lower front edge of the roof.  This is the same place where a lot daylight was visible when I first looked at the trailer.  It will be thoroughly waterproofed when the time comes to undercoat the floor to prevent this from taking place again in the future.

Trailing edge assembled.

Fitting and clamping the leading edge plate.

Drilled, glued, and fastened together.

Finished up just in time - the day is over!  Current time:  5:30pm.

The leading edge plate and the trailing edge still need to be cut to create the angle for the roof to curve up and over from front to back.  This will take place after the glue has had plenty of time to cure and harden.  The rim frames will also be cut after the undercoating is applied.  I'm leaving them in place while the floor is being man-handled on and off the frame to maintain additional rigidity.  Once the floor is bolted down to the trailer frame, they can be trimmed to their correct length.  But I'm left with one little problem now....where do I park the car???

This is only temporary - otherwise I'll be sleeping out here!

What a day!  I'm bushed!



 Postscript:  I was able to rearrange things tonight so I won't have to sleep in the garage!

It's tight but I made it....with room to spare!