Moving on to the drivers side for the aluminum install. Process is the same as the passenger side, just a couple lessons learned to prevent scratches on the aluminum facade is to tape every surface the router base will come in contact with.
I sanded the back side of the aluminum with 80 grit sand paper to roughen the surface and then wiped down the aluminum with denatured alcohol to get rid of any dust from sanding and to remove any oils that remained from manufacturing.
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| Surface Sanded and Prepped for Adhesive |
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| Sheet Laid-up on Drivers Side |
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| Driver Side View 2 |
From the inside I drilled 1/2 inch holes at the ends of the radii to mark the corners of the door, then taped the perimeter where the router will run.
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| Holes for Door Cutout |
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| Door Cutout View 2 |
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| Driver Side Trim-off Complete |
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| Driver Side Trimming View 2 |
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| Aluminum Shaving Everywhere |
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| Aluminum Shaving Inside the Trailer |
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| Installed Marker Lights on Passenger Side |
Before I complete the sheathing on the roof, I need to finalize the courtesy light install and verify the connection is good. I will have access to the wires from the inside through the switch, but it will be difficult. These LED's have a service life of 17 years when running 8 hours per day so replacing the fixture will not occur in my life time!
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| Last Area of Roof to be Sheathed |
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| Triangle area without Insulation is the Switch Location for the Courtesy Light |
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| Testing of Courtesy Light Driver Side |
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| Testing of Courtesy Light Passenger Side |
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| Sheathing Installed and Electrical Runs Marked Out |
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| View From Galley Area |
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| Edges Trimmed and Fan Cutout Complete |
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| Fan Cutout from Inside |
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| Driver Side Door Installed |
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| Driver Side Door View 2 |
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| Tape is the Location for Drilling the Radio Antenna |
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| Skinning the Battery Box - Driver Side |
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| Battery Box Skinning -View 2 |
It's nice to see the finish product come together. I have not quite figured out all the edge trim requirements yet and how I will form this stuff around the radii's but this step is just around the corner........ no pun intended!
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