- 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
Bond Prepping Floor Steel Hardpoints
Just Prior to Bonding Steel Hardpoints
Bonded and Clamped Hardpoint Showing Foam Insert
Clamping Bolt in Middle of Hardpoint
Drilling Hardpoing Mount Holes
Urethane Foam Support Blocks
Chamfering Panel Edges
Chamfered and Cleaned Side Panel
Lower Extrusion Fit Check
Lower Extrusion Fit Check Corner
Reviewed Bond Primer Requirements
Protective Floor Paper
TC Supplied Sausage Guns Worked REally Well with the Korapur 140
Applying Korapur 140 to Forward Floor Edge
Applying Korapur 140 to Forward Floor Edge
Bonded Forward Lower Extrusion
Applying Korapur 140 For Side Extrusion Bond
Cleaning Korapur 140 Squeeze Out from Side Extrusion Bond
Bonded Side Lower Extrusions (Aft Extrusion Will Be Bonded At A Later Time)
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