Hi newbie questions about building an ultralight!

[Slickman]

Hello, This is my first posting....I am yet, another newbie looking to build an ultralight. Not by choice exactly though. You see Id like to build a bigger sized teardrop with all the bells and whistles.....But reality set in yesterday when I checked out my load rating on my truck. I have an S~10 Chevytruck with a 2.2 L, 4 banger engine. Max load rating is 2,000 Lbs. However Id like to keep my teardrop at 850 Lbs max, or preferably even less, fully loaded. I know my truck could handle more, but I dont want to over do it. It drives kinda slow already, and I cant imagine how fast it would go with tow loads near the max. Also I plan to drive some longer distances, across states possibly, and I really dont want to burn out my engine in one go.

With that said....Can anyone give me some hints as to specifics that will really keep the weight down? I was thinking of useing insulation sanwiched between very thin plywood, and then with thin birch strips or veneers on the outsides of that.

I guess a lot of this will be trial and error....Good part is that Im in no major rush to get this thing done....As long as its finished mabe by next summer in 2008.

By the way....There was another posting by a newbie about this same subject and a few members pointed out to Rolys ultralights in the (Hall of Fame) I cant seem to find his gallery or photos though.

Thanks in advance for any help!

[mikeschn]

Slickman,

Welcome to the forum.

I started building an ultralight once, but I got sidetracked.

It's not that hard though... start with a light chassis... a HF 4x8 with a couple cross members removed...

Then build insulated walls with 1/4" plywood or aluminum. Same thing for the roof.

Keep us informed, and keep us in the pictures...

Mike...

[Miriam C.]

to the playground Slickman. Mike's ultra lite showed great promise as does Roly's stacker and half Nelson. Find the ultra lite here: http://tnttt.com/viewtopic.php?t=7565

And Roly's here: http://gages-56.com/roly.html

Also you might try Jeanette's http://tnttt.com/album_ ... er_id=1919

There aren't too many traditional teardrops that weigh more than you can tow.

Enjoy and keep the bubble oil level.

[Sam I am]

Welcome, Slickman!
You mignt save some weight by minimizing the cabinetry in your galley and interior. I've seen some teardrops with beautiful cabinets in the galley and cabin. Some looked like 3/4" thick oak, and were sturdy and gorgeous, but must have weighed over 100 pounds! A counter top and a couple small shelves will work well to start. You can always add more stuff later. I used laminated pine shelving for my galley counter - cheap, and fairly light weight.
Sam

[weasel]

Don't let the 2.2 fool you, I've owned 2 popups 10' and 12' Both 1000 to 1300 lbs. Pulled anywhere I wanted. Plus other trailers with gravel,wood,sheetrock etc. I built a Weekender on a 5x10 frame that can be used as trailer if I ever scrap the tear. Weighs around a 1000 lbs. Not finished but the S-10 pulls good. Its 3/4 and 5/8 ply with ripped 2x4's for 2x2's. Lite-weight might be good for some but I perfer some weight. Stay around 900-1100 lbs and you'll be fine. Oh and welcome!!!!!

[asianflava]

Fully loaded, I estimate my 5X10 tear to be about 1400-1500lbs. That would still give you plenty of headroom with your towing capability. If you really want to build a tear in the 800lb range, you can easily do a 4X8 to weigh that much.

[Slickman]

I was actually really hoping to build a 5 x 10 under 1000 lbs...Sounds like that might be outta the question, huh....Or else Id have to seriously leave some things out....

One thing is for sure, Id much rather have really nice 4x8 with everything than a 5x10 with lots of stuff I wish I had.


I know my truck can pull that much, and some have told me about their own experience with the 2.2L engine....But i just had a new crated engine put in my truck in 2006 because the last one blew up during a road trip...The engine bearings went and there was metal flakes flowing through the engine oil on the highway....Not a fun experience and I guess im just trying to keep this engine around longer this time by not pushing it. Good part was that the truck was under a limited warrenty so the new engine only ended up costing me about $1000.00. That included the the tow to the dealership....The bad part is that it didnt include the price of the rental car I needed for three weeks.

[weasel]

My 2.2 could blow goin' down the street, but with 145K and oil changes every 4-5k I'll go anywhere. My only concern is the fuel pump hasn't been changed. Another thing on weight, I haven't weighed mine on scales since its not done. But weighed everything as I built, so estimated is.... Trailer rollin' 400# and weekender body 700#. For 1100 lbs total. Weighed the frame,axle,wheels... Plywood by size etc. etc. and added. Don't let the weight issue fool you I think you'll be ok!!!

[asianflava]

I was actually really hoping to build a 5 x 10 under 1000 lbs...Sounds like that might be outta the question,

Heh heh, so was I. Mine weighs 1150 so I missed the goal by a little bit. The thing is, when I weighed it, it was minus food and bedding. You figure a a loaded cooler weighs probably 40lbs, the bedding about 10lbs, the EZ-UP (which travels in the trailer) is another 50lbs, a 10lb bag of charcoal, etc it adds up quick.

I probably could have met my sub 1000lb goal if I removed the airconditioner, removed the battery and went AC only, used a lighter matttress (memory foam is heavy), and made simplier cabinetry. The aluminum skin also added a lot of weight.

[mikeschn]

I got as far as modeling up the 4x8 HF chassis. It weighs 160# without the wheels.

You can easily build a 66" wide teardrop on top of a 4x8 chassis. If you are careful, I am sure you can build the lightweight teardrop that you want.

I am planning on modeling a lightweight teardrop this weekend, inbetween building my ET, and normal maintenance around here. I'll let you know what I come up with.

Mike...

[Roly Nelson]

Slickman, if you really want to go "Light", check out my Album pics of the 1/4 Nelson Stacker. Only 249 lbs, total.

Roly

[Alphacarina]

Slickman,

Building a teardrop isn't terribly difficult (easy for me to say . . . . I've never built one) assuming you have average carpentry skills and can absorb and follow the hints given by those who have gone before you . . . . but building an ultra-light one sure is

Weight is even more of a concern for me than you with your S-10 because my tow vehicle is a 2 liter Mazda Protege . . . . which Mazda says shouldn't tow anything so I began just like you . . . . wanting a 5 X 10 at about 1,000 pounds . . . . maybe 1200 loaded

I collected most of the bits and pieces to get started and then I ran across a super deal on a Little Guy trailer. It's only 4 X 8 and is marginal in most every regard, spacewise, but it has composite walls, insulated to R-7 and a 2 X 3 inch box steel frame and it weighs 660 pounds empty. I honestly don't see how you could come close to that weight building walls with plywood . . . . but I guess nothing is impossible, if you have the time and money, though weight is a funny thing. You could weigh every single piece you put in your build and expect it will weigh say 800 pounds and then when you roll if over the scales . . . . surprise!

My 660 pound 4 X 8 is here http://www.golittleguy.com/cms/available-models/model-information/4-wide-retro-6.html and then they also make an 800 pound 5 X 8 here http://www.golittleguy.com/cms/available-models/model-information/5-wide-retro-2.html

All weights are unladen of course and you could easily put 250 pounds of camping goodies into either one. This is for a very simple trailer with no kitchen, or running water, no battery, no A/C etc, etc - Mine already has air installed and a 12 volt deep cycle battery and no doubt I'm getting near 800 pounds . . . . still without any camping gear, for a miniscule 4 by 8 trailer with less than a 4 foot ceiling (42 1/4 to be exact . . . . less with the mattress in place

Good luck with your build - Shoot for 800 pounds empty and if you come in under 1200 pounds, you'll really have something to be proud of, especially for a first effort

Don