Another Milestone Reached in the Teardrop Build

As you probably know by now, the sidewall construction of the teardrop is a sandwich of poplar stringers and two layers of 3/4" rigid foam insulation between inner and outer layers of 1/4" Baltic birch plywood.  The original wall build left the outer layer of plywood off so we could run wiring through the walls.

Today, we finally added that outer layer.  The first photo is of the first piece attached.

First we spread glue on the mating side everywhere it would make contact with the trailer structure. We then used a pneumatic stapler to attach the plywood to the structure.  Note the pencil marks that served as guides.  The darker blocks (crosshatches) indicated areas to not staple because wires run behind.  Note that the door and window openings were only rough cut and will be trimmed with a router.  Likewise, the top profile is rough cut.  Once the plywood is installed on the front and top the sides will be trimmed to match the actual installed roof.

Port side complete:

 
Starboard side complete:

 
The next step is to cover the top in two layers of 1/8" Baltic birch plywood.  While the inside of the front/roof has only a single layer, we opted for two layers externally to better resist any potential impact and provide a better foundation for the covering.