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Beveled the Borealis Panels

Yesterday I beveled the #5 and #4 panels on the inside edges where they will eventually meet.

ALTERNATIVE STEP FROM THE OFFICIAL PYGMY MANUAL: The Pygmy manual suggests using a rasp or such to do this. That is probably good advice, however I used a router table.

To do so you have to 1) have someone help you, 2) have a lot of room (roughly 34'), and 3) be damn careful.

I got the router set up outside my garage near the end of my long work table. Then carefully adjusted a 45 degree bit with a roller on top to just the right level. To make sure I used some of the scrap 4mm boards that come with the kit. The top of the panels ended up barely meeting the roller.

My wife helped me and she carefully held the panels such that there wasn't much stress put on the main middle seam (remember I'm only putting fiberglass on the inside of the panels and not the outside). Then we slowly ran each panel through the router table. It did a fine job in most places but there were a few spots that I had to then go over with a rasp and clean up. But... no big mistakes or gouges! Phew!

In the picture below you can see that it did a pretty nice job... at least in that stretch. 


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