I’ve been taking the second build of the galley hatch very slowly and deliberately. Where the last time I tried to glue a lot of wood at the same time, with things slipping a sliding all the while, this time I would place just a few pieces at a time, make sure they set true, let the glue cure, then move to the next. Also key this time was doing most of the gluing in-place.
I guess I wasn’t in a picture taking mood for the first step. I routed new ribs and did the first round of gluing in the shop. 
The frame went back on the trailer. 
Detail of the frame corner. II only used four screws to secure the initial square. Everything else is held with wood glue. 
I used wooden spacers to make allow for the spaces needed for hardware. Here you can see the even 3/8″ space around the trailer edge that will allow for the hatch to rest against the rubber seal that will go on the trailer edge. 
Carefully fitting the first of the support struts. 
I kept a portion of the old hatch handy to remind me of what worked and what didn’t as I built the new one. 
A quick test to make sure that the hatch lifts were in the right place. 
One quick visit to the shop to add the supporting ribs that work around the gas lifts. 
Getting close to completion.
In between bouts of gluing we put layers of varnish on the interior. This required multiple coats with sanding in-between. Watching varnish dry is slightly less interesting than watching paint dry.
We also had time to wire up the running lights.
We are getting really close to completion. The galley hatch still has plenty of steps to go, but that’s pretty much the main focus at this point. There’s some final exterior finishing to do, and some galley cabinetry puzzles to solve. But mostly it is crossing steps off the galley hatch list!
Dear K & M, This is truly a work of art! I think it ought to go right to the Smithsonian. WOW. One query? Wil there be wheel covers, or fenders?
In Ashland, OR with the Hazel to see a few plays. Aloha, Jeff B
Yes! Fenders coming soon! As soon as we get another coat of paint and epoxy on the exterior, which is my job today.
You left out the cussing parts.
Ha! No kidding!!