- Started habitat assembly sequence planning
- Sent out quote requests for water jet cutting aluminum roof hatch adapter plates (dedicated blog post about this topic to come in the future)
- Inspected and touched up subframe paint
- Laid habitat floor panel upside down on floor
- Prepped habitat floor steel hardpoints for bonding
- Dry fit hardpoints in floor
- Rounded edges of hardpoint straps to ease foam installation
- Bonded and installed hardpoints and foam in habitat floor panel
- Drilled and tapped one central hole in each hardpoint to clamp
- Re-positioned truck and habitat floor in shop for habitat assembly
- Pilot drilled and tap drilled mount holes in habitat floor
- Clearance drilled fiberglass at hardpoint holes
- Tapped hardpoints in habitat floor
- Reviewed bond primer requirements
- Ordered Sika SP-205 (from EMI Supply) to prime aluminum to bond with Korapop 225.
- Cut high density urethane foam blocks for floor support during habitat assembly
- Bonded terry cloth to top of foam blocks with 3M 77
- Removed clamps and temporary bolts from bonded hardpoints
- Chamfered and cleaned lower edge of habitat floor panel
- All panel edges had a lot of gel coat build up that needed to be removed and the edges needed to be softened. Previous fit checks show that this was a required step to get the panels to fit well in the extrusions.
- Flipped, leveled, and positioned habitat floor panel
- Chamfered and cleaned upper edge of habitat floor panel
- Chamfered and cleaned all edges (including passthrough cutout) of forward panel
- Rearranged panels and extrusions in shop space
- Chamfered and cleaned all edges (including all cutouts) of left and right side panels
- Dry fit checked all lower extrusions
- Measured all panels and extrusions (again)
- Checked flatness of floor on support blocks
- Masked floor panel with heavy paper
- Bond prepped and bonded forward lower extrusion using Korapur 140
- Bonded several adhesive test samples using Korapur 140
- Finalized order of water jet cut aluminum roof hatch adapter plates
- Additional measurements and fit checking
- Measured back wall panel height in preparation for cutting steel hardpoints
- Bond prepped and bonded both side lower extrusions using Korapur 140