|The Rondack Lodge
Phyll's Custom Fenders!
Design Copyright 2007, Steve Frederick
|Frame||Exterior Walls, Body||Floor Assembly||Phyll's Fenders||Cabin Interior||Galley||Electrical/Plumbing||Finishing/Details||Voyages|
|Here's a shot of Phyll's favorite fenders! I made a pattern from a scale drawing as a starting point.|
|I made a pattern from a left-over section of the profile pattern.
|I fastened the pattern to a piece of 2" foam board. Using the router and a guide bushing, I cut out the fender blanks. I'll carve the fenders from this foam.|
|Here's the block and the pattern it was cut with. I'll make another!
|Here's the second one! I laid it on the pattern to see how it is going to look.|
|Using the same
pattern. I cut backers for the foam. These will get glued to the foam
and will serve as a guide to carve to, and as a mounting point when I
fasten them to the body.
|All of the parts are ready for the glue-up! I'll use Gorilla glue for this, as it sands easily, and works well with foam.|
gluing up the blocks, I sanded them to shape. I kept them back to back
to ensure that they were as close to identical as I could get by hand!
|Here's a profile shot of the curb side fender. There are a few chips in the foam. I'll deal with that in the next step!|
|I filled the defects with a schmutz of epoxy and wood flour. I also sealed the foam with a coat of epoxy.
|Here, I have the fenders on some threaded rod supports. I have two layers of 4-oz 'glass so-far. I'll sand this fair, then apply more layers of 'glass.|
|Using the opening in the side of the trailer as a pattern, I made inner supports for the wheel well liner.
|Looking through the whell opening in the wall. You can see where I will fasten the liner.|
|I got some wacky wood from Boulter Plywood. It curves really well, so, it's perfect for the wheel wells.
|I just nailed it in place with PL construction adhesive, and staples.
Next, I'll seal the area up with fiberglass and epoxy, then paint it.
order to get the 'glass to conform to a sharp curve, I used plastic
wrap! Just smooth it over the wet lay-up, and it works like a mold!
|Another shot of my plastic wrap mold! This is my last lay-up on the fenders. Next I'll build up a few coats of epoxy and then start sanding!|
|I used some free glass that I got on an automation job at a fiberglass factory. It's 20-oz stuff, made for boats!
|Once I had the wheel wells sealed up in 'glass and epoxy, I prepped them for a covering in bed liner.|
|I got a rattle can of bed liner from the local auto parts store.
|I think it looks pretty cool! I didn't fill the weave..adding to the "cool factor".|