Oh Boy. Do I feel rough.
I've somehow managed to have the flu twice in 3 weeks!....with a decent week in-between? Fortunately I managed 3 hours on Sat morning to get just a little more done.
I decided to do the cut-outs for the rack supports but went with a compromise to leave an extra 5mm all round. They may not be the exact size triangles as they were previously....but let's face it, I'm never going to return the whole vehicle to original and concourse.
I think even 5mm extra all the way around will help to support the weight that might go up there just a little better.
I also sized the long sides more accurately. When I bought the ply, I got them to do the long cuts for me. I asked for 197mm (as measured from the originals). After he'd ruined one whole sheet of ply by firstly cutting it to 195, I asked him to have another go. From the next new sheet he tried again, and this time got 199mm. For him, that was close enough and he went on to cut the next one 'the same'....but it was actually 200.
So, I marked my planing line at the 197 on both and having planed very close, I finished them off with a belt sander that rolls on cylindrical wheels at each end. I remember being told how every mm matters in the assembly if I want it to open easily or not leak! I get stressed every time I imagine putting it all back together again.
So, having got the first crucial 6 pieces made, my plan now is to get them stained and varnished, attach the rubber seals and then, with the arch still suspended as it currently is on its rope, get it all put together. I think I'll then be able to try out the old end pieces for size.....and make the new ones according to how it all goes. To me, this seems a better plan than making the ends now....and then finding they don't fit, especially if they're too small and I have to get more new wood!
Amusingly, I counted all the screws I removed and I've been and bought stainless ones. I've got the Sikoflex too but I haven't found any closed end rivets yet. I've not used internet and delivery as I hate this...so....who stocks them in actual shops?!
So...back to the Lemsip and day-time TV
Bye for now.