For some reason, Jason and I actually slept in on this fine Saturday morning. (usually we’re up by 6!) This meant that we got way later of a start than we had planned on..

So yesterday I cut the holes for the windows, however I ended up cutting the big window too small because there was an inner seal piece that I didn’t notice.  We essentially ended up cutting a 1/4″ ring out of the window. Ohwell I guess. Better than cutting it too big!

The window on the other side is a port hole window meant for a boat.  That doesn’t really matter functionally, but it does have a built in drain port that we have to cut into the shell.

While test fitting the big window we realized that it was meant for a 3/4″ wall and we have 1/2″ walls.  Looks like we just found a use for that little piece we just trimmed out!

After the windows were all trimmed up and test fit, we moved on to the fiberglass part of the day. But first, we had some loose ends to sand down etc.

Remember that big laminated beam that we cut and installed a few posts ago under the cabover? It’s time to sand that down and get it ready for fiberglass.  I used power tools, but didn’t get around to smoothing it out yet. That’s for tomorrow.

Next we decided to tackle the inside fiberglass corners. Pretty straightforward, just a lot of strips of glass and a bit more time to make it all smooth.

That set up pretty quickly in the sunshine that finally came out right when we started the fiberglass. By the time we finished up the corners, it was time to start on the gasket sealing lip surface that I glued on yesterday. We decided to use 6oz fiberglass instead of the 1708 because I wanted a sharp corner and the 6oz had a better shot of being able to make that happen.

That’s 2 layers of the 6oz glass tape around the outer edges.  We wanted to put another layer on the inside, and I even glued the gusset piece under the lip so the glass could make the bend, but it wasn’t having any of it.  We did the aft edge and then gave up.  Tomorrow we hope to be able to flip the camper upside down to finish the outside seams and maybe we can get it without gravity trying to pull the wet glass off of the foam.

I’m going to have to get up earlier tomorrow so we can get more done!