Ultralight Stripper AKA "Less is More"

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

Work continues

Postby Larry C » Sun Jun 20, 2010 8:25 pm

Most here would have their build done by now with the time I have spent so far.

My goals of light weight and water resistance have me thinking like the boat builder I already am.

I hope I am not boring everyone with my obsession with light weight and super water proof methods incorporated in my build. It's just the way I am!



Larry......

Here's my recent progress:

Assembling my recycled pressure treated picnic table wood into my 5X8 floor. Epoxied and screwed.

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1/8" Russian Birch epoxied coated and attached with thickened epoxy, narrow crown staples and clamps.

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1/8" Skin epoxied on to frame:

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All underside surfaces coated with epoxy:

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Warming epoxy in a nasty sink:

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Mixing epoxy with micro ballons and a little wood flour for color, to fill staple holes:

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Filling holes with easily sanded epoxy/micro balloons mixture:

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Using a utiliy knife blade as a scraper after initial cure:

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Plywood trimed with router and surface sanded, ready for glass:

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Glass cut and layed out. Dry brush eliminates wrinkles.

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Glass wet out coat:

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Waste fiberglass trimed with razor blade:

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Light sanding after first fill coat (thin glass):

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Final fill coat rolled on tipped off with foam brush:

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Counter bored screw holes pluged with thickened epoxy and wood dowels:

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"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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Ultralight Stripper, update 7/11

Postby Larry C » Sun Jul 11, 2010 5:30 pm

Work Continues:

Added more bracing to floor, all epoxy coated.

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Foam glued in with thickened epoxy....

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Boxes of books and staples hold down the door skin ply, thickened epoxy for glue.

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Staple holes filled...

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Using up some small pieces of fiberglass glass cloth.......

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Fiberglass wet out with epoxy......

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My new stress skin panel consists of 1" X 1-1/8" pressure treated Southern Yellow Pine.
This is from a 20 year old picnic table. The lumber is not like what you find today, it's straight grained, dry, and strong. Epoxy sticks to it very well.
The top and bottom skins are 1/8" plywood with fiberglass on the top and bottom. All internal and external surfaces are epoxy coated, including the foam. Everything is glued with thickened epoxy and internal cracks/voids. are filled with the same.

With the fiberglass on the top and bottom, I can now lift one corner of the 5X8 floor without it bending at all. I need this strong foundation as my frame is just a triangle and the body will be a major part of the strength of my tear.

I will paint the bottom and varnish the top. The completed 5X8 floor weighs 60#


Stay tuned, the frame has been welded..........

Larry
"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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Postby kennyrayandersen » Sun Jul 11, 2010 8:00 pm

Nice -- keep it up!
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Postby Miriam C. » Sun Jul 11, 2010 10:29 pm

:applause: :thumbsup: That is a lot of work for a floor! Good job!

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Frame Welded

Postby Larry C » Mon Jul 12, 2010 6:48 pm

Here's my frame:

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[img]http://www.tnttt.com/gallery/image.php?image_id=68037[/img[/img]
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"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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Postby wlivesey » Wed Jul 14, 2010 7:30 pm

That's a great looking ultralight frame. I'll be watching this build... Did you have the frame build or did you build it yourself?
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Postby Larry C » Wed Jul 14, 2010 8:29 pm

wlivesey wrote:That's a great looking ultralight frame. I'll be watching this build... Did you have the frame build or did you build it yourself?


Hi Bill,
Thanks for the kind words!

Andrew graciously redesigned a 5X8 Ultralight frame from his 4x8 Pico frame design for me. However, I was not comfortable with the Flexride stub axles only being available in 550# or 935# capacity. I was looking for something closer to my 500-600# total weight trailer goal.

I really want an axle around 650-750# range. Dexter 8 can do this.

Sooo........ I took Andrew's 5X8 Pico/Ultralight design that he did for me and incorporated into his Ultralight design. His Ultralight design uses angle iron for the tongue. It also was designed for the Dexter 8 Axle.

I already had everything cut using 1" X 2" tubing, so I just modified it somewhat to work with the Dexter 8 axle. The design is a marriage of 2 of Andrew's great designs.

Sorry to be long winded, but credit for the design and a little background of how I got here is worth mentioning.

Anyway, to answer your questions: I did all the planning, procuring, cut all the steel and layed it out ready for welding, however I had a pro welder friend come over and do the welding.

BTW/ the cross piece is not part of the frame, it's just a tempoary brace till I get my axle.
"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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Postby Chuckles2153 » Thu Jul 15, 2010 8:00 am

Hey there Larry,
Just happened on to your build and needed to chime in on it. I'm very impressed with the frame design :thumbsup: and the way you built the floor is way cool.
How much weight are you anticipating you trailer will weigh when finished?
Chuck
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Postby aggie79 » Thu Jul 15, 2010 8:28 am

Larry,

Every step of your build is a work of art - first the laminated perimeter frames, then the torsion box floor, and now the frame! You're going to set a new standard to attain!

Tom
Tom (& Linda)
For build info on our former Silver Beatle teardrop:
Build Thread

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Postby Larry C » Thu Jul 15, 2010 12:05 pm

Chuckles2153 wrote:Hey there Larry,
Just happened on to your build and needed to chime in on it. I'm very impressed with the frame design :thumbsup: and the way you built the floor is way cool.
How much weight are you anticipating you trailer will weigh when finished?
Chuck


Chuck,
My plan/hope is 500-600# total loaded tow weight. Right now my floor weighs 60# and the bare frame weighs 45#

Larry
"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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Postby BC Dave » Fri Jul 23, 2010 12:40 am

wow doing some great thinking in that TD.

I'll be watching a rooting;

I can see your a prefectionist and craftsman!

It should look smart when you done.

Cheers BC D
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Any updates or progress Larry?

Postby MotoRandy » Tue Mar 29, 2011 11:18 pm

We would love an update to your build.

Thanks,
Randy
Phoenix, AZ
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Re: Any updates or progress Larry?

Postby Larry C » Thu Mar 31, 2011 11:24 am

MotoRandy wrote:We would love an update to your build.

Thanks,
Randy
Phoenix, AZ


Randy,
I hope to get back at it soon. Thanks for the interest...

Larry C
"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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Postby pete42 » Thu Mar 31, 2011 11:35 am

Larry when I was building an all fiberglass airplane
we use a hot wire to cut the foam
hot wire was stainless aircraft wire and a toy train transformer.
worked very well we were building two at a time not the way to do it.

good luck on a very nice build.

pete
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Postby Larry C » Sun Jul 24, 2011 6:36 pm

I am finally getting back to my build. I would like to make a change from my original plan. The design is following Mike's Ultralight profile, but it will have a smooth outer surface sandwich wall. I like the side profile, and it's already started, but I would like to change one thing.
I would really like a different door profile. I am open to suggestions. I would like to keep the same door width, and location front to back. If anyone can help me with a different door shape to fit the side profile, it would be appreciated. xy coordinates in the same location of the original door would be easiest for me to duplicate.

If you see a reason why my idea of a different door won't work for the Ultralight profile, please let me know.

Here's the Ultralight pdf:

http://www.mikenchell.com/TheUltralight.pdf

I would like something similar to this:

http://i886.photobucket.com/albums/ac62/KentuckyBryan/teardrops009.jpg

Larry C
"If its worth doing it's worth doing Light"

http://www.tnttt.com/viewtopic.php?f=50&t=35852
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