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Seaghan's
Teardrop TrailerTools

Teardrop: Assembling the Hatch

Seaghan

Framing the Hatch was one of the chores I feared the most. Both because if it didn’t work perfectly, I’d be disappointed, but also because I’d ended up struggling with and frustrated.

I already knew that the frame was not square from side to side, but I had to make sure that the frames would give the appearance of a smooth skin and not buckle or pinch.

Instead of building the hatch and then seeing if it fits, I decided to build it in place. I started by clamping the outer ribs in the correct location, using shims to ensure that I had the right spacing.

Next, I started cutting the horizontal spacers. The first time I didn’t make sure the spacers were in line… it didn’t occur to me, or the original builder, that you could assemble them in a single solid line using pocket screws, and since the floor, I’ve become the master of pocket screws.

What’s a pocket screw, you say? I’m glad you asked. Imagine that you take a piece of wood and you’re going to drill a hole through the wood. You hold the drill perpendicular to the surface, right? That would be 90°. But, if you want to drill out the end of the wood, you need to tilt the drill bit to as much as 10° to the surface.

When you do that, you end up with a long slice, or pocket, in the surface, but it means that the screw is completely hidden and you can even fill the hole with a dowel, cut it off at the surface and the screw is completely hidden. Not necessary for this project, but the technique is highly adaptable and quite useful.

What? What? I’ve lost you? Okay, just look at the photos. By-the-way… this little jig should be added to the list of tools you can’t live without.

Another design change at this point was to go back to our original cooler. It was smaller, better designed and fit under the counter with enough space for the stove… something the new cooler didn’t allow… so we returned it.

Also, the plastic water jug was replaced with a stainless steel jerry can. I’m looking to start marketing these, so if you’re interested, let me know.

I used the template for the ribs, but they proved too narrow to be able to router, therefore...
... I used the jigsaw, clamped them all together and then belt-sanded them to a consistent curve.
Using spacers, I built the two outside ribs first, leaving the centre one for last.
Note that we've changed the cooler and water jug. I don't like plastic containers and this one is stainless steel. Likewise, our old cooler just needed a clasp to secure the lid... also made out of steel and ABS.
The hurricane hinge set in place to ensure that the gap that I left for the hinge was accurate. I thought it was a bit excessive, but turns out it was perfect.
The centre rib in place, I used my template for screws run across it to see how the curve was. Turns out it was perfect.
Closer shot of my screwing template. I'm a big believer in templates... especially if you want consistency.
The hatch structure complete. You'll see later where I've removed these horizontal ribs and made it a straight line across for a more pleasing line of screw heads using a pocket screw.
Pocket Screw Jig by Kreg
Start by setting the thickness of your wood and the aligning the line where you want your pocket screw to exit.
Clamp the jig and the wood to your working surface... and I highly recommend you splurge for the Kreg clamp designed for this job...
Set the stop around the drill bit at the thickness of your wood.
Drill into the hole with the bit until the stop hits the jig.
Your pocket has been perfectly cut...
...and the screw will exit the centre of the wood. No more guessing.