Method for making a mobile home ceiling construction

A method of manufacturing a unitized ready-to-install mobile home ceiling structure comprising the steps of:

• (A) placing a plurality of generally rectangular panels on a tunnel jig cambered along its longitudinal axis with the longer sides of the panel generally perpendicular to the longitudinal axis of the tunnel jig abutting longer sides of said panels at joints in edge-to-edge adjacent relationship forming an overall generally rectangular cambered panel arrangement having front and back face surfaces;
• (B) back fastening a roof frame to said panel arrangement by means of:
• (i) applying at least one bead of adhesive material across the back face surface of the panels in correspondence with roof frame truss member spacing intervals;
• (ii) positioning the roof frame on the cambered panel arrangement contacting the back face surface along bottom chords of the truss members and along side edge rails whereby the side edge rails and opposite outer truss members reside along the perimeter of the panel arrangement at the back face surface thereof;
• (iii) tightening clamping means at opposite terminal end portions of the truss members thereby arching the bottom chords creating close contact across the span of the truss member with the cambered back face surfaces of the panels and compressing said adhesive material therebetween;
• (iv) driving staples at spaced intervals along the bottom chords of truss members intermediate said outer truss members, wherein said staples are driven at an angle of from about 30.degree. to about 60.degree. to the back face surfaces of the panels, the staples penetrating the bottom chords and back face surface of the panels but stopping short of piercing the front face surface;
• (C) front fastening the panels along substantially the full perimeter of the rectangular panel arrangement by means of driving fasteners upwardly at the front face surface of the panels along said perimeter thereof, said fasteners extending through the panels and penetrating the side edge rails and penetrating bottom chords of the outer truss members;
• (D) untightening the clamping means;
• and,
• (E) transporting the roof frame and panel arrangement from the cambered tunnel jig as a unit providing a ready-to-install unitized mobile home ceiling structure wherein the set-up time of the adhesive material does not restrict moving the unit.

A method of manufacturing a unitized ready-to-install mobile home ceiling structure comprising the steps of:

• (A) placing a plurality of generally rectangular panels on a tunnel jig with the longer sides of the panels generally perpendicular to the longitudinal axis of the tunnel jig abutting longer sides of said panels at joints in edge-to-edge adjacent relationship forming an overall generally rectangular panel arrangement having front and back face surfaces;
• (B) positioning a roof frame on the panel arrangement contacting the back face surfaces along bottom chords of truss members and along said side edge rails whereby the side edge rails and outer truss members reside along the perimeter of the generally rectangular panel arrangement at the back face surface thereof;
• (C) back fastening the roof frame by means of:
• (i) driving staples at spaced intervals along the bottom chords of truss members intermediate said outer truss members, wherein said staples are driven at an angle of from about 30.degree. to about 60.degree. to the back face surface, the staples penetrating the bottom chords and back face surface of the panels but stopping short of piercing the front face surface;
• (ii) applying a foam adhesive along at least one side of the bottom chords of the intermediate truss members at the back face surface of the panels;
• (D) front fastening the panels along substantially the full perimeter of the rectangular panel arrangement by means of driving fasteners upwardly at the front face surface of the panels along said perimeter thereof, said fasteners extending through the panels and penetrating the side edge rails and penetrating the bottom chords of the outer truss members;
• and,
• (E) transporting the roof frame and panel arrangement from the tunnel jig as a unit providing a ready-to-install unitized mobile home ceiling structure wherein the set-up time of the adhesive does not restrict moving the unit.