We cut the 4'x8' aluminum sheet down to roughly the size of the hatch and cut it with the jigsaw. (It worked eons better than cutting the diamond plate.)
After that was done, I applied a liberal amount of contact cement and we let it dry for 15 minutes and then put the aluminum on and clamped it since the strap was being used on the teardrop.
The aluminum had popped up in the front of the teardrop so we took an aluminum trim piece and installed it on top of the aluminum and diamond plate to hold it in place.
We finally got to put on the trim! We first ran butyl tape for a waterproof seal on the edge of the whole side and then place the trim on and pre-drill through the aluminum and into the sidewall. Dan then drove 1 1/4" exterior screws into the molding every three inches. After cleaning it all up and using a scraper to clean the butyl tape that pushed out from under, we added the black trim and we were done with one side.
Knocked out side two in about half hour since Dan had to keep changing bits.
Last step with the roof was to route out the hole the MaxxAir fan is going to sit in. You always need to have air flow in a teardrop as since it's a small, airtight space, it can totally kill you. No bueno.
We used the recommendation from Vintage Technologies and used the rotozip drywall bit with guide point and it worked like a dream! We sprayed it with the silicone WD40 and it went perfectly.
We're getting SO CLOSE to being done and we are SO THRILLED with how it looks!!! 🤩🤩
We are hoping to be finished in around 10 more hours. I also realized I'm not dual counting hours where both of us are working on it. I count my hours and then Dan's and then our joint hours as the same so I suppose it's not incredibly accurate. 🤷🏻♀️
Total time spent today: 6.5 hours
Total project hours: 117.5 hours
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