Hey All-
Just like nearly everyone here, I'm a long time lurker. I am not really sure when I first learned about TDs, but I think it was around spring 2013 because my girlfriend and I drove cross country that summer (visiting National Parks) and I distinctly remember making a point to see if we could find any TDs. I recall passing one somewhere in WY and it was red and beautiful and being towed by a mkv VW TDI wagon (I have an 03 TDI wagon).
Anyway. The time has come where I'm ready to take planning seriously. So seriously, in fact, that I have a few TD items in my possession: a Fantastic Fan, side marker lights, a third brake light, a hurricane hinge, a new router and a piece of birch plywood to start cutting up for some woodworking practice (never done it before...). I also have a sort-of profile cut out on a piece of 1/4 ply.
My first goal is to get a trailer built (roughly 5x9). I am not a welder (though I'd like to be - it's on my to-do list) so I am going to have someone weld it for me. My goal is to keep the total trailer width to 79" or less, so I don't have to run additional markers on the fenders and the three lights on the top. Also, a narrower trailer will fit better behind my TV. North American towing restrictions put a 1,000# tow limit on my car, so weight conservation is also on my radar. I did two a 5x8 uHaul box trailer from NH to MT this summer and I just learned that the empty trailer is 900# (according to the uHaul website). My car didn't even notice when it was behind me. I did notice the trailer when it was fully loaded - so I was aware of my speed and following distance and took appropriate precautions. Back to the frame. I am thinking of building along the lines of the Atma Travelear frame, with a few modifications.
Question time:
1) What type of steel should be used? Mild?
2) How are you all mounting your spare tires under the trailer (I would like to do this because I'm planning on having a bike rack set-up on the tongue so this is both the next logical place and will help balance out the tongue weight)?
3) I can't seem to access the trailer tongue page, but can I substitute 2x2x11ga angle for the two legs of the A Frame tongue (I'm planning on having a center tongue (2x2x11ga) run to the second cross member)? I seem to recall reading somewhere that the tongue bracing doesn't really increase the strength, it just prevents it from twisting.
4) Mitered corners-vs-butts. Should this be decided by my welder?
5) I feel like this will result in many opinions, but... what/how do you recommend painting the frame? Clean it with mineral spirits and then a self-etching primer?
General construction plan:
Floor is 1/8 sandwich with 1x poplar framing and 3/4 insulation (same for walls)
Profile... oh, profile. Simplicity (and what's on the 1/4 ply) is a Benroy-ish shape (24" radius on front). Pic will come later, I think I have one... I am not in love with the Jelly Bean profile, though I do like the Teardrop NW profile:
and I also like the Silver Shadow profile as well. Why 9'? We want to have our Coleman cooler tucked in lengthwise, and we also have a Chocolate lab who will have to sleep in the TD when it's cooler outside. We're hoping to camp more into the shoulder seasons with the TD than what we do with the tent.
I plan on skinning with FG and epoxy, something I've never done but I'll practice on the underside of the floor first. I'm thinking 6oz. cloth. I'd like to finish the interior with a Danish oil finish, as I feel that putting poly on everything will make sound echo and it will feel "cold".
The only part of the electrical which I am still trying to figure out is how to charge the TD battery while I'm driving. I initially was thinking of running 12v back from the TV and tying it in to an inverter, which is then tied to a Noco genius 7.2 amp charger. I realize there are inefficiencies with this system, however, I need a charger regardless. Plan B is to run 12v back from the TV in to a solar controller, which I can then modify to also run off of solar when at camp (later down the road). Thoughts?
I am still waffling back and forth between a Frederick or not style hatch seal. I haven't made up my mind yet. That's one of the biggest hurdles, actually. How am I going to end the back of the hatch?