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Old 12-26-2012, 04:59 AM   #194 (permalink)
Galane
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Join Date: Jul 2009
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For shaping the rabbet style lip joints around the hood and hatch, here's what I'd do.

First, figure out the depth of the cut from the outer surface. Cut a short block of wood that thickness.

Second, figure out the width of the lip and cut the block of wood to that width.

Third, Connect two boards together in an L shape. Cut the boards to the same length as the block, but a but wider so that when the block is placed into the V of the boards they project past it.

Fourth, clamp the block into the V of the boards drill a hole through the block and one board. Insert a teenut in the block's hole. Counterbore the hole so the teenut flange is flush with the surface.

Fifth, wrap sandpaper around the block, poke a hole through the paper on the side opposite the teenut then bolt the block to the L boards.

Now you have an automatic depth gauging rabbet sanding block. :-)

With some modification this design can be used to carve the rain gutter you'll need along the sides of the hatch. You'll also want to make certain to have room for a closed cell foam weather seal around the hatch. There are a wide variety of shapes of automotive weatherstripping available in bulk rolls. Check with RV and boat suppliers.
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