after some not teardrop related trouble again a little progress,
It`s 1/4 Birch Plywood. First challenge was to get the ply, second to bring it home. The sheet is 9'10"*4'11" (300*150cm), remember my small car? I loaded it onto the roof rack, under supervision of grinning woodworkers. Strapping it down it bend lengthwise and became pretty stiff. I met no cop...
Big challenge was to get the very flexible big sheet (like paper) onto the glued frame without smearing the glue all over the sheet.
So i put the frame on top of the sheet and marked the outlines. Then i put the frame in level and the sheet into position and put two nails in, one left one right, the pliers show the position of the left. I tilted up the sheet and put the Plastic box under. This allowed to put the glue on 3/4 of the frame. As i had the nail-hinge the sheet found its position perfectly in the first try. As i have no stapler i nailed it to the frame. That`s cheap... . Having nailed half of the sheet i removed the hinge-nails, tilted up the other side, put glue on and nailed it all. Lastly i sunk all the nails with a nail punch to put more pressure to the glue and to get them out of the way for sanding.
Last step was to saw all sides, to get the ply to the right size, get rid of the excess glue and to get a squared surface for the walls. Therefore i sawed the timber slightly as well. Now the surface for attaching the walls is perfectly square and flat (the timber was not).
The 1/4 birch ply is more then strong enough. You can walk on the floor without an unsafe feeling. Maybe it is possible to break it with a karate- footkick, but not by kneeling, even with no mattress.
weights are:
axle 50lbs
tongue 22lbs
clampings 6lbs
3 wheels 25.5lbs
lighting, fenders 7lbs
frame 40lbs
floor ply 33lbs
total 184lbs (84kg) now, the rest up to 660lbs (300kg) is for the walls, the roof and bed and ...comfort.
Greetings, Bernd
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