Felixx's Superleggera - It is ROAD LEGAL!

[felixx]

So I went to the shop today;
Got 2 x 17mm and 5 x 4mm okume ply


I couldnt fit the other 17mm (floor) on as the roof was beginning to get dents in it

Then after failing a WOF on the Anglia (leaking rear shock - arrgh)
I made some sawdust:




Mrs Felixx saw how small it will be and called it a "Coffin on Wheels"

[Ned]

Frank there will be in depth pictures so you guys can give me advice as I have NEVER seen a TD in the flesh (just like you) - when you were building yours.

I am quite excited as I have never built anything like this. Mrs Felixx thinks I am mad

That's because you ARE mad :-P
Happy to see progress. I'm still working out ideas in solid works before I start with mine. I better hurry though, nats isn't far away!

What you doing trim wise? Pretty cheap from the states if you wanna add some to my order?

[dales133]

Free shipping to aus? .
Are you making your own doors?

[felixx]

Hi Dale
Yes I will be making my doors
This is a learning process for me too

[dales133]

Braver man than me but I totaly com end you on that.
A got factory doors at great expense but I don't want it to leak!
As soon as I'm finished this one I'm going to make a more traditional one alot cheaper and make my own doors.

[dales133]

I expect to be into this one 5000 aussie easily by the time I'm done

[felixx]

Well I got my steel for my trailer chassis all cut today

And I stuck some together-



(My welding is getting better)

The good news is that the diagonals are within 2mm of eachother. I am very happy
(also I tagged em up in the garage but it is too messy to photograph in there just now)

I also have a dilemma;
I have been pondering the weight of aluminium laminate and I really am thinking it will be too heavy. I also love the look of woodies and wonder if 4mm Okume ply with several coats of polyurethane will be durable (I have a spraygun so can blow a coat over her every year) or should I put aluminium and spray it?

Please give me some pros and cons.

Also I have 3 cross beams to add, should I space them evenly or place one under my galley wall divider and space the other 2 evenly?
Sorry for the noob questions

[dales133]

Well Felix let me walk you through the design changes I've made.
I was going to make a lightweight steel frame with composite pannel outer and thin ply inner and for a bunch of reasons I changed my mind and one was insulation the other was moisture transfer and obviously weight.
If you have the tools and skills I'd try to talk you into a stick frame because so far it's working for me and your not restricted by sheet sizes.
If not skelitonised 3/4 ply.
My walls only get 3mm ply on the outside now and 1.2mm aluminium at this stage but that still may change yet.
The roof will definatly be play and as they stand I can easily lift them with one hand and not much weight to add.
Maybe 3kg

[felixx]

Hi Dale
I am using skeletonised ply.
I am keeping this one to the 8x4x4 dimensions.
I appreciate your feedback.

[Sheddie]

Great to see things happening.
On mine the side walls 3/4" ply with holes cut out to shed some weight. If I was to do it again I would cut more out, but at the time I was a bit unsure exactly where I was fitting inside cabinets, and we were only a couple of days into the build when the walls went up. I think it was 4mm ply on the inside and we used 4mm acl on the outside. The roof is 4mm acl direct onto the beams. You can also get the acl in 3mm sheets. When you are adding up the weights for a ply exterior, don't forget to ad in the weight of the tin of polyurethane. The thing with the acl that really worked for me was that as soon as it was glued on it was finished.
As for the x beams on the trailer frame, you shouldn't need one under the galley bulkhead, if it is attached to the floor it should be self supporting. I have only got two x beams on my frame that is 3m long and 1.5m wide. After all, your weight on the floor is spread out over the bed, and how much weight are you going to have in there. Have a look under your bed at home, how many steel beams are there across under that? Apart from stopping the floor from sagging a bit the x beams are only there to keep the side beams parallel.
Thats a bit more for you to think about.

[felixx]

Thanks Frank
Im going to think on this

Oh I got 2 x formica benches for $1 each and some drawers for free
12 sets of drawer runners, 30 and 40cm, rated to 40kg for $1-$4 each (won 3 auctions on trademe)
also my switches for Lights, Fan etc arrived

I pick up some fiberglass mudguards tomorrow too

[KCStudly]

You're on your way now!

I went with 2 intermediate xmbrs, 1-1/2 angle, and placed them where I wanted the attaching bolts for the floor to be; about evenly spaced on 9'-8" frame length. (Though I do have additional wooden xmbrs in my built up floor.)

That weld looks plenty strong; no worries. I like that you made sure to weave and tie both sides of the weld in, and your weave is consistent showing good speed control. Now that you have those techniques you could probably narrow up your weave, which will have the effect of speeding up your travel speed a wee tad, perhaps lower the heat a smidgen but maybe no need to with a faster travel. That would tighten up your heat affected zone, reduce your rod usage, and limit the under cutting (...if that is what I am seeing). Just a little refinement. Was it a single pass, or did you have to fill the root at the tube radius first? (With stick I'm thinking it was a single pass.)

[felixx]

Hi KC
I did a single pass to fill the curve and ground it flat
Then I did my 2nd pass.
Thanks for the positive feedback.

(We had visitors this morning so I welded in the 3 crossmembers, if 2 is good, then 3 must be better!)

I get my leaves, coupling etc on sunday. I might have a trailer for next weekend! That will surely speed things up

Now Im am off to make my front radius bigger, I miss read the plans and made a 770 radius arc only 300! (Silly old me)

edit:
Here is my apprentice 'helping' (the Jigsaw was unplugged!)
(you can see the piece I removed from the front radius as well)

[Sheddie]

(We had visitors this morning so I welded in the 3 crossmembers, if 2 is good, then 3 must be better!)

That probably used up the weight difference between the ply and acl exterior.

I get my leaves, coupling etc on sunday. I might have a trailer for next weekend! That will surely speed things up

Wow that sounds exciting. It's a lot of fun when the bits start arriving.

Now Im am off to make my front radius bigger, I miss read the plans and made a 770 radius arc only 300! (Silly old me)
edit:
Here is my apprentice 'helping' (the Jigsaw was unplugged!)
(you can see the piece I removed from the front radius as well)

That's looking better. I thought it looked a bit blunt in the front. You had better stand it up and take a picture so we can all see.

[felixx]

I will tomorrow, with my new guards (fenders)