Teardrops n Tiny Travel Trailers

I've copied the exterior AC system from Shadow catcher.
However, I just made a cardboard prototype for a plenum. After my success skinning my TD with polyester cloth, I decided to see if I could do the same with the plenum.

Here is an interior pic of the plenum [IMG]http://uploads.tapatalk-cdn.com/20160222/b2302834941723321a92d128ba7c1876.jpg[/]
I considered remaking the plenum from luan, but I decided I might as well try what I have first.
I've cut two pieces of poly cloth like this
One will cover the outside, one the interior.
I'm just using straight titrbond 2. One coat under the cloth, one coat above. Here is the bottom after about 12 hours

And one side after about 1 hour.
I'm doing one side at a time so I can keep the wet side up for better adhesion. I'll paint with exterior paint once all the side are covered with fabric
Tom

Always fun to see how others run with an idea. I was fortunate to find some one who works with HVAC willing to make the plenum for not much.

Shadow Catcher wrote:Always fun to see how others run with an idea. I was fortunate to find some one who works with HVAC willing to make the plenum for not much.

The truth is that I'm skeptical this will work, and by the time someone bought glue/fabric/paint and some sort of insulation, a sheet metal version might be cheaper. However, this stuff is in the garage, and I was a little bored this weekend.
Tom

I am reminded of the one builder who made his teardrop out of three ply cardboard and chopper glassed it, he had pictures of him standing on it. But made the note that he spent a lot if time sanding off the pointy bits.

Social Tom, welcome to this project venture. As Shawdow Catcher said, it is great to see other ideas. I built my first experiment out of unprotected box material (corrugated board) and wrapped it with duct tape. I worked well for awhile, but all the condensation soon took a toll and it ended up,like all,corrugated material subjected to moisture.

(The side window concept is only for test purposes. I created a separate vent system through the back floor)



My first guess is that your cloth will do a good job to protect the corrugated material. But what happens when a crack or pin hole develops? I suspect water will work its way into the core. Vibration just from jousting around in the TD or TV could also hasten any weak points into cracks. But taking your idea a step further, what if you used a waterproof material such as those political signs, etc. They could offer the stiffness of a box and a surface for the glass cloth. And they would not weaken when wet.

I like the sheetmetal idea first and then maybe your idea over the 1/4" plywood idea that I went with. Mine works, but is heavy and bulky. When it is time ti replace it, eaither because of age failures or the need to make a new one for a new AC unit, I should be looking at your idea or Shadow Catcher's.

I agree with your concerns. I don't think the glue/paint would stick to the smooth plastic well. It might be ok over luan, probably smart to add a drain hole, and make sure it leans back away from the plenum. I'm pretty lucky, I camp in the desert, and condensation seldom occurs and I've only needed it about 2x per year over the last couple of years.
Tom

This was made with 1/4 plywood and aluminum angle.Not heavy at all.

I like the aluminum angle bar. Lighter then my wood. And compact too. I went too big I think. And I see you moved the controls to the box. I also like that idea over my allowing for doors to reach inside the box. Another example to follow for the next one. Good job.

Oh, BTW, I used 1/2 in insulation of the inside in my attempt to control condensation.

What are you using for the flexible ducts?

Mine were 6" dryer aluminum ducts from Lowes.

Sparksalot wrote:What are you using for the flexible ducts?

I'm using 5 inch exhaust hose for a portable ac system.
I think I got it here
http://www.appliancezone.com/a6200-280-danby-air-conditioner-exhaust-hose/?gdftrk=gdfV210715_a_7c4877_a_7c17817_a_7cA6200_d_280&gclid=CjwKEAiAo7C2BRDgqODGq5r38DsSJAAv7dTPrSZ-G04HjWaDRToZOUxwDIip_deA9kpB1kBJbjv2lRoC6tbw_wcB
The OD is 5 inches, so I had to shrink the metal collar a little bit. But it fits the deck plate nicely with a couple of layers of duct tape it screws in.
Tom

One of the reasons I wanted the controls inside the trailer was so that it would be easy to regulate temperature and to make it weather proof. I had an expensive thermostat which did not play well and just pulling the one out of the AC, the right price, and it works.

I leave mine on high cool, the the most at dial is set about 6 . I must unplug it to turn it off. With the side mount hoses it easy to pull one off and twist a dial if I want. ( plus it spent most of last summer in the window of my sons room). However I rarely adjust it once its set.
Tom

That is sort of what I did during my trials in August. But I have not really tested it in real life so I do not know what will really happen. For example do I leave it on high during the day and lower at night? We will see.

lrrowe wrote:That is sort of what I did during my trials in August. But I have not really tested it in real life so I do not know what will really happen. For example do I leave it on high during the day and lower at night? We will see.

Last trip I turned it off at night, because it cooled off pretty fast at dusk. Previously I just left it on high. The hose set up makes it really pretty quiet, the thermostat will cut back the compressor automatically when it needs to.
Tom