Jonathan has been a regular visitor to the site and owns a 1966 Dormobile in need of restoration. The Dormobile is a father & son project that’s being restored as time permits. Jonathan contacted me last summer to inquire about building a bulkhead jig (like the rotisserie jig pictured above) to be picked up this spring. Jonathan and his father are going to make the trip to New England to pick up the jig, check out the shop, visit Lanny Clarks shop, and make a parts run to Rovers North.
The steel for the jig……….1.5″ square tube and 3/16″ sheet.
Time to cut.
The chop saw makes quick work of the heavy tubing.
All of the frame parts cut and prepped. Tomorrow I’ll drag out the plasma cutter to cut out the footing supports from the 3/16″ plate.
Lanny Clark lent me an untouched original Series 2 bulkhead to build the frame of the jig around……guaranteed accuracy.
Time to cut the 3/16 plate…..out comes the Hypertherm Plasma cutter.
If you buy a plasma cutter, get yourself a pair of these, shade #5.
I use whatever might be handy as a straightedge guide for the plasma torch.
About five minutes to set up the Hypertherm Powermax, and made this 17 inch cut in about 10 seconds. HUGE time saver.
Nice smooth cut.
All of the parts to construct a bulkhead jig.
Squaring up the main frame.
These clamps are made by Strong Hand tools. They’re not terribly expensive and do a great job of holding your angles during welding.
Once the outer frame is welded up square it’s time to place the bulkhead inside and position the top hangers. Once the hangers are welded in place it’s time to construct the more critical footing mounts.
All the pieces for the footing mounts…….the blocks are machined and all holes are drilled on the Bridgeport. The tube it turned down so it’s a press fit into the square tube and the face block.
Pressed together, this will now be bolted to the bulkhead footing…….this will dictate the position for welding the fixture to the outer frame of the jig.
Footings fixtures welded in place to the outer frame. The footings stay bolted together and will be tig welded…….tig will be a cleaner weld and produce less heat, the goal is for these footing fixtures to stay straight and true.
Tig welded up and they stayed strait as an arrow…..the bolts dropped right out.
Strong Hands tools to the rescue again.
Not only will they hold a tight corner, but they also straighten out and have a V-block feature the will hold round stock in place for welding.
Base welded up.
Nearly complete. I’ll add some chain (about 4′ per side and anchored to the base) and hooks on the lower left and upper right of the frame. The chain will allow the bulkhead to be positioned and held anyplace in the jigs 360 degree rotation. After that it will get a coating of POR15 to keep the rust bug away.
Sure makes bulkhead work a little less painful.
Tilt – A – Whirl