Alaskan Benroy

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Alaskan Benroy

Postby ratrod71 » Wed Nov 26, 2014 2:20 pm

Hello Fellow Teardroppers, my name is Bryan and I live in Fairbanks Alaska. I first introduced myself in the Newbie section, but I thought I would start an official "Build Journal", so please forgive the duplications of text and images. Here we go.

This is going to be a 4X8 with a Benroy side profile. 3/4" plywood floor and walls. Insulated roof. Manufactured side doors.

I built the frame using 2X2X.125" steel tubing. This includes the perimeter, cross-members, and tongue A-frame. These first pictures are when it is in raw steel freshly sandblasted, then etch primed, and finally topcoated with urethane single stage paint.
Attachments
Frame a.jpg
Raw steel and sandblasted.
Frame a.jpg (44.89 KiB) Viewed 4332 times
frame b.jpg
Primed with etching primer.
frame b.jpg (42.22 KiB) Viewed 4332 times
frame c.jpg
Topcoated with urethane single stage paint.
frame c.jpg (45.22 KiB) Viewed 4332 times
Alaskan Benroy build journal: viewtopic.php?f=50&t=61738
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Alaskan Benroy

Postby ratrod71 » Wed Nov 26, 2014 2:26 pm

On the rear corners I welded a plate to accept the stabilizers. I drilled 3 sets of holes to give me options as to how they could be mounted. I.E. pointed back, at a 45 degree angle, or out to the side.
Attachments
frame j.jpg
Stabilizer mounting plate at the rear of the frame
frame j.jpg (44.83 KiB) Viewed 4328 times
frame k.jpg
Stabilizer mounted at a 45 degree angle
frame k.jpg (46.16 KiB) Viewed 4328 times
frame m.jpg
Stabilizers in the down position
frame m.jpg (59.65 KiB) Viewed 4328 times
Alaskan Benroy build journal: viewtopic.php?f=50&t=61738
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Alaskan Benroy

Postby ratrod71 » Wed Nov 26, 2014 2:30 pm

Completed rolling chassis.
Attachments
frame i.jpg
frame i.jpg (55.04 KiB) Viewed 4328 times
frame e.jpg
frame e.jpg (63.89 KiB) Viewed 4328 times
frame d.jpg
frame d.jpg (57.34 KiB) Viewed 4328 times
Alaskan Benroy build journal: viewtopic.php?f=50&t=61738
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Alaskan Benroy

Postby ratrod71 » Wed Nov 26, 2014 2:40 pm

For the axle I ordered a Dexter #9 built to the specifications I provided. Hub width is 60.5", mounting flanges are 43", the start angle of the swing arms is 10 degrees down, and the weight rating is de-rated to 1500Lbs. I called Dexter and talked with them about the dimensions that were needed. They then plugged the info into their computer program and e-mailed me the results so I could verify that everything would fit. Such as swing arm to the sides, wheel offset, and fender width requirements.
Attachments
frame n.jpg
frame n.jpg (50.77 KiB) Viewed 4326 times
IMG_6688.jpg
IMG_6688.jpg (38.7 KiB) Viewed 4326 times
IMG_6692.jpg
IMG_6692.jpg (42.5 KiB) Viewed 4326 times
Last edited by ratrod71 on Mon Mar 21, 2016 8:00 pm, edited 1 time in total.
Alaskan Benroy build journal: viewtopic.php?f=50&t=61738
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Alaskan Benroy

Postby ratrod71 » Wed Nov 26, 2014 2:48 pm

I am using 3/4" ACX plywood for the floor. The perimeter wood is clear poplar that was custom cut to 1 1/2" X 2" true dimensions. The floor will be channeled over the frame. This will give the plywood walls a strong surface to be glued and screwed to.
Attachments
IMG_6702.jpg
IMG_6702.jpg (50.49 KiB) Viewed 4319 times
IMG_6681.jpg
IMG_6681.jpg (59.03 KiB) Viewed 4319 times
IMG_6682.jpg
IMG_6682.jpg (41.15 KiB) Viewed 4319 times
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Alaskan Benroy

Postby ratrod71 » Wed Nov 26, 2014 2:55 pm

The screws used to attach the plywood to the poplar are coated deck screws with Torx bit heads. The fasteners used to hold the deck to the frame are 3/8" stainless button headed allen cap screws with nylon locking nuts. The glue used is Tite-Bond III.
Attachments
IMG_6661.jpg
Deck screws
IMG_6661.jpg (36.56 KiB) Viewed 4317 times
IMG_6684.jpg
Allen cap screws
IMG_6684.jpg (43.28 KiB) Viewed 4317 times
IMG_6694.jpg
IMG_6694.jpg (32.1 KiB) Viewed 4317 times
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Re: Alaskan Benroy

Postby KCStudly » Wed Nov 26, 2014 3:09 pm

Very nice! :thumbsup:

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Re: Alaskan Benroy

Postby noseoil » Wed Nov 26, 2014 6:16 pm

Welcome & want to see more! Looks like a good start on the build.
Build log: viewtopic.php?f=50&t=60248
The time you spend planning is more important than the time you spend building.........

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Re: Alaskan Benroy

Postby AlgoDan » Thu Nov 27, 2014 5:25 am

Welcome aboard Bryan, looking good and looks like you have a plan.
Here now but Camping later.............Dan

Build Journal
http://www.tnttt.com/viewtopic.php?f=50&t=54681
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From .................Paper...........................To.......................... Pavement............................
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Alaskan Benroy

Postby ratrod71 » Sun Nov 30, 2014 5:26 pm

I spent our snowy Fairbanks Sunday waterproofing the underside of the deck. I used the West System epoxy 105 resin, and 206 hardener. Applied 2 coats per their recommendation. I bought more than I needed, so I will be waterproofing the sides also prior to installing the aluminum skin. An inexpensive alternative to the West System foam rollers is the Wooster brand. Their foam roller named TIZ, part number R730, worked perfect and was purchased locally for less than half the price of West's. I know, the picture is kind of boring, but I thought I would throw it in. Happy Building, Bryan
Attachments
IMG_6710.jpg
Waterproofed deck using West System epoxy.
IMG_6710.jpg (43.47 KiB) Viewed 4160 times
Alaskan Benroy build journal: viewtopic.php?f=50&t=61738
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Alaskan Benroy

Postby ratrod71 » Sun Dec 28, 2014 1:06 am

I cut out the sides after drawing the arcs with compasses made from 1X2's with a screw in one end and a hole drilled in the other to accept a pencil. I used the exact dimensions shown in the "Generic Benroy" plan. The plywood is 3/4" birch. I am going to use pre-made 26"X36"doors. After cutting the sides out I used West System epoxy and coated the exterior side.
Attachments
IMG_6986.jpg
Freshly cut sides made of 3/4" Birch.
IMG_6986.jpg (31.31 KiB) Viewed 3962 times
IMG_6987.jpg
Cool little leftover corner pieces to be used to square up the side walls.
IMG_6987.jpg (34.1 KiB) Viewed 3962 times
IMG_6995.jpg
Laid out to coat with epoxy.
IMG_6995.jpg (61.06 KiB) Viewed 3962 times
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Alaskan Benroy

Postby ratrod71 » Sat Jan 03, 2015 8:56 pm

Today the deck got permanently mounted to the frame. I first put down camper topper foam tape on the frame prior to mounting the deck. This will keep the wood from chafing against the frame and make a waterproof seal. Then the sides were screwed into place. The mahogany spars are next including the framing of the opening for the Fan-Tastic Vent fan. Once evrything is mocked up and screwed into position, I will disassemble the spars and sides, then glue it up with Titebond III and permanently screw it together. This was a fun day!
Attachments
image.jpg
image.jpg (201.62 KiB) Viewed 3882 times
image.jpg
image.jpg (215.81 KiB) Viewed 3882 times
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Alaskan Benroy

Postby ratrod71 » Sun Jan 04, 2015 8:07 pm

Today the Alaskan Benroy got the roof spars and framing added for the Fan-Tastic Vent roof fan. :)
Attachments
image.jpg
Roof vent spars and framing.
image.jpg (184.78 KiB) Viewed 3838 times
image.jpg
Roof vent spars and framing.
image.jpg (184.2 KiB) Viewed 3838 times
image.jpg
Fan-Tastic Vent roof fan.
image.jpg (182.22 KiB) Viewed 3838 times
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Re: Alaskan Benroy

Postby Redneck Teepee » Sun Jan 04, 2015 11:27 pm

Looks like things are coming together very nicely. Nice work too! :thumbsup:
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Re: Alaskan Benroy

Postby KCStudly » Sun Jan 04, 2015 11:59 pm

Looking good! :thumbsup:
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