Helpful ReplyHot!Master Plan, Part Deux ....

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Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/02 19:22:57 (permalink)
Well, let's just call that PAR ... for how today went.
Just deleted my entire post.
 
Lets try this again.
 
So  ....  if you had tuned in to yesterdays episode you will remember that ME - I - this guy - the flippin rocket surgeon ....
Carried a heavy burden. Namely the weight of the canopy.
 
I impressed myself by carefully cutting away about 2/3 of the mass from the center of this canopy.
Set in the Styrofoam, so that that there was not a hollow in the middle.
Laminated the THIN sheets of aluminum to it all.
Clamped it all down, added all kinds of weights etc.
Let it dry over night.
 
It all looks good this morning.
Glue is dried.
I test fit a trim piece, and wow, nice fit.  Much better with that extra aluminum.
 
Now its time to fix up the trim.
Re drill some of the holes and counter sink them.
Polish the dullness out of them.
That nobody but me will notice.
 
OK and hour or so later I remove all the clamps and weight off of the canopy and put stuff away.
and..
waaa??
Holy crap 
This thing feels kinda heavy again.
Did I miss a clamp?
W T F ???
 
Must just be me.
Must need another coffee...
Nope, dang this thing IS heavy!
Drag out out the scale...
Ok Yup.... I'm still  ..... well lets just say the scale was workin.
Grap the canopy.
W T F !!!
The fricken thing weighs in at 40 pounds again??
 
Weigh it again.
Yup 40.
 
How in the he...???
It's just fricken glue and aluminum F F S    !!!
 
So needless to say I just achieved absolute negative gains for all that time and effort.
I can't explain it.
Maybe I shoulda just used styrofoam and the aluminum sheet?
 
But the screws would have nothing to bite in to.
 
If there were ever a time to use that bloody saying I hate so much, this was it.
It is was it is.
 
I spend the next hour trying to get my truck out of what used to be a gravel parking spot in the back yard.
Which seems to have turned into a mud bog with all the snow melting.
 
Lucky for me, it wasn't the 1 foot deep ruts that were holding me back as much as it was the bumper that got peeled back as it got hung up on the fence.
 
I could feel one of the ruts collapse into pure mush as the truck suddenly lurched back and to the right...
And as if there was no longer a fence holding me back ....... there was no longer a fence holding me back.
Ya gotta love it when a plan comes together.... or comes apart.
 
Free again ...Free again...Free again
 
I probably needed to pull that part of the fence out anyway.
Clearly it is not compatible with my truck.
 
After an hour of clearing the debris field, I was able to pull the truck up beside my garage.
Where I quickly learned how much taller this truck is than my last one.
Needless to say, my next trip to Home Depot will involve a tour down the eves trough isle.
Hey, there was a debris pile there anyway.
 
Believe it or not, I DID manage to get the canopy installed.
Even close up, it looks not bad.

Next I have to tackle the struts.
I went and got some 80 pound struts. Just to be safe.

Now I have to figure out how to make the strut mounts work.
The canopy side is easy.
But I can't attach the other end to the window frame.
It's just too flimsy.
I want it good and solid.

Funny how the window looks so much smaller now.

 
There is still a tweak on the bumper.
I rested it against my old pickup truck and persuaded it back into place.
post edited by Blakkmoon - 2017/04/02 23:49:58
#61
Inferno
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Re: Master Plan, Part Deux .... 2017/04/02 23:18:26 (permalink)
What size is your truck?
#62
Inferno
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Re: Master Plan, Part Deux .... 2017/04/02 23:19:10 (permalink)
Is it diesel or gas? Where you live you probably want gas because of the temps.
 
#63
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/02 23:48:14 (permalink)
It's a gas truck.
Ford 5.4
Single rear wheel 1 ton
Just shy of 20 feet long tip to tip.
Kitchen should be roughly 7x7x12   ( will be slightly less once all the walls are installed )
post edited by Blakkmoon - 2017/04/02 23:51:48
#64
Inferno
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Re: Master Plan, Part Deux .... 2017/04/03 00:20:01 (permalink)
That's a pretty small kitchen area, what are you going to sell?
#65
Inferno
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Re: Master Plan, Part Deux .... 2017/04/03 09:42:44 (permalink)
Have you done any work on the inside?
#66
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/03 10:16:59 (permalink)
If you think this is small, you should have seen the first truck I was working on. This thread.
6 wide 6 high  10 foot kitchen area.
 
This is my first time.
I didn't want some 45 foot beast of a truck.
 
To get even ONE more foot of kitchen length, means going up one more size of truck.
( which are hard enough to find )
 
But this increases ALL of my expenses. Long term, not just the build.
 
One size up means going to a dual rear wheel set up.
Automatically this means it has to be safetied EVERY year.
My brother runs big trucks.
He tells me to expect a minimum of 5 grand a year for that. Just because they can.
 
A bigger truck increases my GVW, which increases my insurance rates a LOT.
 
It means I can't fit it in my yard. And I can't park it here anyway. And I can't park it on the street beside my house.
So I am paying for somewhere to park.  Probably a storage facility, because we don't need to go to a commissary.
So there is another $1500 a year.
 
Here, trucks under 22 feet pay one licence fee, while trucks over 22 feet pay double, for the privilege of parking in a metered spot.
I don't remember the exact fee, but I know the bigger trucks pay about $2000 more. That's for 6 months.
No pro rating, no short terms, all or nothing.
 
So on average I would be getting roughly an extra 10k hit every year.  Not cool. Especially when we only go for about 6 months out of the year.
So I would have to pull an extra  20k in sales over 6 months to justify it all. ouch.
 
That's a LOT of grilled cheese to sell.
#67
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/03 10:20:13 (permalink)
Inferno
Have you done any work on the inside?


Nope.
If you read through all my stuff, you will see, I just got this truck a couple months ago.
We have been suffering -30 temps for most of that time.
And I don't have anywhere INSIDE to work.
 
We just finally started getting nice weather over the last week.
Literally - 2 weeks ago it was -25.
#68
Inferno
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Re: Master Plan, Part Deux .... 2017/04/03 15:11:54 (permalink)
I live in Wisconsin, so I know cold weather too. I was working on mine out in my driveway all winter long. I remember a couple of the -30 days too. The cold came up through the diamond plate and turned my feet into ice blocks, even with the kerosene bullet heater running. Good times, yeah right!
#69
hpx
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Re: Master Plan, Part Deux .... 2017/04/03 16:50:00 (permalink)
Blakkmoon
Inferno
Have you done any work on the inside?


Nope.
If you read through all my stuff, you will see, I just got this truck a couple months ago.
We have been suffering -30 temps for most of that time.
And I don't have anywhere INSIDE to work.
 
We just finally started getting nice weather over the last week.
Literally - 2 weeks ago it was -25.


Hey Blakkmoon, we have been in high 80's low 90's everyday here bud. Shorts and a/c 24/7.
 
As for the small kitchen, I am working right now on a clients trailer. It is 7x7x7 cube (built off a pop-up camper base) Putting a sub shop into it. No grill or fryers. Everything is cold. It has been quite the challenge to fit it all in, but it also has worked out nicely. With a huge kitchen area I think too many people feel they need to fill every last inch with something and lose the chance for a smooth flow or rhythm. A small kitchen forces the concept of efficiency. I have enjoyed this build and am so impressed by the versatility of scaling down to what is really needed, I may begin offering this same sort of design to new clients. A scooped ice cream place Or a mini donut/cookie/cupcake/bakery would be perfect for this size. Easy to tow and easy to park most anywhere, a 10' festival space would be no problem at all, I may have stumbled on a whole revenue stream that I can pop out in just a few weeks that someone could genuinely make a darn good living out of.
post edited by hpx - 2017/04/03 16:53:53
#70
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/03 20:04:43 (permalink)
THANKS for the weather update.  
My buddy lives down there in Ocalla.
Love to rub it in every chance he gets.
 
Inferno -  I love Wisconsin.  Not as harsh as here. But just enough to kick your butt.
Was in minneapolis a couple weeks back. Weather was pretty good.
Love driving through Wisconsin when we hit Milwaukee in June.
 
Yeah, I don't have any issue with the kitchen size.
 
I don't plan to have 4 or 5 people in the truck.
I don't plan to have 75 items on the menu.
 
Keep it simple.
#71
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Re: Master Plan, Part Deux .... 2017/04/04 17:32:59 (permalink)
Simple is the way, be great at few things instead of average at a lot of things. Good call.
#72
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/08 10:36:56 (permalink)
This explains so much.
Re-Store was having a sale last week.
This was my bill.
Wife pointed it out today.
It all makes sense now.

#73
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/08 12:00:32 (permalink)
Installing the struts was WAY harder than it should have been.
Of course, never done this before.
No instructions.
No clue.
Where to mount?
Pivot point? Pressure point?
Weight to height ratio?
Drag coefficient?
All trial and error.
Got it figured out in the end.
 
You would think ( at least I did ) that the strut would have to be mounted further out on the canopy for stability.
But it does not work that way.
I did it similar to this:



 
Close the canopy, figure out where the frame side mount will be with the strut compressed.
I added an inch, to be safe.
Then prop the canopy open and figure out where the canopy side mount will be with the strut fully extended.
 
Not sure why, but most places seem to suggest mounting the struts in this position.
With the fat end on the door side.
Maybe so water can't run down into the cylinder when it rains?? Not sure.
 

 
My struts were the ones with ends like these that just pop over the ball mount.
 

 
While they just POP on, they do NOT pop OFF.
They BREAK off pretty quickly though.
Found that out pretty quick.
There is a little spring tab that you have to remove first. DUH!
 
Also the 80 pound struts were WAY to strong. It actually made it hard to close.
It looked like that would eventually cause damage somewhere.
I don't know the math ....
But I have a canopy the weighs 40 pounds.
And I am using 57 pound struts.
It's stable. Not hard to close. And opens smoothly without POPPING up.
 
I was able to buy theses mounting brackets, which worked great on the canopy side.
 

 
But once I figured out the frame side, I needed the opposite kind of brackets.
And spent the day driving around trying to locate some.
Guess how THAT turned out....
 

 
Ended up having to make my own.
Tried some lighter stuff.... no WAY!
They flexed when I closed the canopy.
Had 2 x 2 1/4 inch angle.
Cut down the width to about 1 1/4 inch.
Smoothed the corners and welded on the studs that came with the struts.
 

 

 

 
The big problem was that it HAD to be mounted to the window frame, which was thin and flimsy to begin with,
plus it had no structure behind it to carry the weight load.


Here is a shot of the solution from the inside.
On both sides of the window, I was able to MacGuyver a chunk of 3/4 inch C channel between the window frame and the factory stud.
I tried with a piece of square channel, It would not budge.
Then I cut little pieces of 1/2 inch C channel down to insert into the larger piece to form a box ( support piece ).
Then I drilled through from the window frame into the factory stud, and used screws long enough to hit the studs.
Now it's solid.
 

 

 
Who was it that said doing your own window was going to be easy??
Oh yeah, NOBODY!
#74
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Re: Master Plan, Part Deux .... 2017/04/08 14:58:45 (permalink)
I'm sure glad I bought mine already done. Wow
#75
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/08 20:04:34 (permalink)
If my work here can help even one other person make better choices, then all my sacrifices will be worth it. 
 
This has been a public service announcement.
 

 
post edited by Blakkmoon - 2017/04/09 09:06:54
#76
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/08 20:36:58 (permalink) ☄ Helpfulby paulnye 2017/04/12 16:59:46
Great weather today.
Actually got the inner window installed.
 
It went easier than I expected.
But not without its challenges.
 
The first thing I got installed was the outer lock/handle.
I went with a simple t handle and matching slide mech.
They were not my 1st choice.
They were on clearance at Home Depot.
 

 
 
The challenge with the inner window was spacing.
I did not take into account the extra space required for things like the lock mech or the gas struts.
To compensate for this, I added 1/2 by 1/2 aluminum C channel on the inside of the outer frame.
This gave me that extra 1/2 inch of space.
 

 
It was not too hard to do, but not fun.
End result though, the window is installed.
 

 

 
 
What I can't figure out is this...
I had to cut 3/4 inch off the outer frame to make it fit between the factory beams in the truck.
I then had the trim the same amount from the canopy to make it fit the frame properly.
But I did NOT touch the inner window frame at all.
Yet it fits perfectly to the outer frame.
And I mean fit PERFECTLY.
But I built both windows at the same time, and made them to match. weird.
#77
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Re: Master Plan, Part Deux .... 2017/04/09 07:26:17 (permalink)
Thanks for passing on the experience.
#78
NOSHp20
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Re: Master Plan, Part Deux .... 2017/04/09 21:09:15 (permalink)
A fine effort with good results! One item done, many to go.....
#79
paulnye
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Re: Master Plan, Part Deux .... 2017/04/12 17:04:33 (permalink)
Blakkmoon,
Right now Im also doing my own window, awning, gas springs (pain)
Nice pictures
Although self-fab takes time and a few attempts to get it right, I just couldnt bring myself to shell out the $1000-$1200 for pre-fab,  
Mine cost $170 all in, and its nice.
All left to do is fenagle the springs into place. I forgot to leave room  
#80
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/12 19:23:05 (permalink)
TOTALLY agree with you.
At least you got that really nice window. So you don't have to fab the ENTIRE thing.
I have been waiting to see pics of your progress. DUDE ! I wanna see pics!!
 
Yeah, I forgot about the depth of the struts when closed.
Even had to shave a couple mm off the edge of the mounts on the canopy side.
 
The NICE part of doing the ENTIRE thing DIY, is that when I needed that extra 1/2 inch of space...
It was just a matter of attaching some 1/2 inch channel.
 
THIS has been by far my most used tool so far.
 
 
I don't think my brother is ever going to get it back !!
 
 
#81
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/12 19:27:08 (permalink)
I was working downtown today. ( vending machines )
Today it is FINALLY warm enough for the trucks and carts to start coming out.
Went to see them.
 
I like MY window/canopy better than most I saw.
I'm pretty darn happy with myself now.
 
Tomorrow I start the back doors.
Hopefully get those made, and the roll up door out over the weekend.
Fingers crossed.
 
 
#82
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/14 22:10:09 (permalink)
Started work on the back door.
I am using these steel frames that I was able to salvage.

 
 
Need to cut down the length by 16 inches.

 
 
Left one at 36 inches wide, cut the other down to 24 inches wide.
Had to add an extra brace for the hinge on the bigger side.

 
 
 
All went great. My measurements were spot on all day long.
Except for.... well....  the measurement was right....
But SOME dumbass cut the wrong piece!!
I'd blame my assistant..... if I had one.
Had to section this little piece back in .... DOH!
Good thing my welding skills are improving!

 
 
All in all it went well.
Here is a hot of the test fit.
Managed to keep an almost perfect 1/8 inch gap.

#83
Uncle Groucho
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Re: Master Plan, Part Deux .... 2017/04/15 08:00:50 (permalink)
If you did that all by yourself , you did a GOOD job.
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Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/16 23:19:13 (permalink)
Thanks so much.
And yeah... all me...
Like my wife says.... who else would work this cheap?
#85
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Re: Master Plan, Part Deux .... 2017/04/18 01:12:30 (permalink)
looking good.!!!!!!  
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Re: Master Plan, Part Deux .... 2017/04/25 23:31:44 (permalink)
I know... it's a shelf.
Woo Hoo! Big deal.
But seriously, it WAS a lot of work.
 
A while back, I stated that I was going to use these stainless steel shelves from Ikea.

 
It turns out that these are total crap.
The shelf is SUPER thin metal.
The material underneath it is compressed PAPER!
Not wood, not mdf, PAPER!
 
SO
New plan.

A couple of weeks ago, I cut out the window from the side of the truck.

 
Lots of material to work with.
Using the table saw, I cut around the beams.
Ground out all the rivets and separated the beams from the sheet.

 
 
Then I cut the the beams in half to use them as supports for the shelf.

 

 
And after a day in the garage trying to figure it out...
VIOLA!
 

 
Nice and strong. All aluminum. Color matches the rest of the truck.
40 inches long.  Made 2 of them.
 
Pretty darn impressed with me.
#87
NOSHp20
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Re: Master Plan, Part Deux .... 2017/04/26 08:55:30 (permalink)
/\ "master of re-purpose" /\  well done!
#88
Blakkmoon
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Re: Master Plan, Part Deux .... 2017/04/30 00:21:13 (permalink)
Got the shelves mounted today.  Still some tweaks to do.
Figured I better get it done while there are no walls.
But it makes me think that I am going to make the interior walls on that side somehow .....  
Not permanently attached.... kind of easy to get in to.
So I can do repairs when needed.
 
Even though I am mounting with nuts, bolts, washers, lock washers, and even loctite.
 
When I see these other trucks downtown...  owned by the guys who clearly don't do any of thier own work....
$200 000.00 truck.... but the shelves hanging off one side. Or kind of mounted.
 
Makes me think maybe these shelves take a lot of abuse.
 
My big win of the day....  It's finally nice weather out for while, so I broke out the brand new smoker I bought.
 
I have never smoked anything before.
 
OH MY GAWD!!!
 
I am  A CONVERT!
 
How can I ever go back to oven cooked roast beef???
 
Did up a bunch of med sized roasts.  And SWEET CHEEZUS it was good!!
 
Can't wait to try a few more with some different methods.
#89
NOSHp20
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Re: Master Plan, Part Deux .... 2017/04/30 16:24:05 (permalink)
When you mount the concession shelf are planning on an inside the wall back-up plate in case it get "leaned" on hard? Always time to fire up the grill and experiment!
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