The "Quantumsleep" folding caravan build

[Mitchelkitman]

Hi guys, I hope I've done this correctly as sometimes I get a bit "stuck" with computers (my attempts to add to hall of fame are a good example!)
The process used was to make a very basic female mould using "contiboard" which is a melamine plastic coated woodchip board - it has a good flat surface of satin finish, i.e. not high gloss, but certainly good enough!. I welded the chassis using rectangular hollow section of varying sizes, and an electric arc welder. The mould was created on the chassis using the flat sheets of contiboard and various pieces of timber, to give a "box" to laminate the lower part. The 2 photos attached show 2 stages of the process. I filleted the corners to a radius using plasticine and a glass marble. The mould was then polished with wax many times. Gel coat was applied to the surface, followed by layers of matting and resin in the normal process for fibreglass construction. After several days the parts of the mould were unscrewed from each other and removed from the glassfibre, and then some insulation foam (brand Cellotex in U.K.) was added to create the bumper (fender) shapes and the wheelarch shapes, this was then covered with matting and resin, followed by gelcoat and flatted with abrasive paper until good. The white hinged sides were made in a similar manner on a flat board with edge strip to produce the mould. The top was made again in the same way, but using a sheet of hardboard (masonite in U.S.?) supported by a framework to create a curved top.

[Shadow Catcher]

Welcome to the forum. I will say it is a very interesting build and innovative use of materials.

[mezmo]

Good to see the Build Journal started ! It'll be interesting
to see how you did it, from the obvious great result it achieved.

[Mitchelkitman]

There's not really any more I can add - It was just a case of using the contiboard to construct female moulds, and then moulding the glassfibre in them, and removing the mould after the glassfibre had set.
Glad you like it.

[mezmo]

I'd be curious as to how you determined the hinging and securing
of the ends-sides-corners both collapsed and set up, and
also how you did your weather-stripping for both ways.

[KCStudly]

Be nice to see how you outfitted the interior, too.

[Mitchelkitman]

I'd be curious as to how you determined the hinging and securing
of the ends-sides-corners both collapsed and set up, and
also how you did your weather-stripping for both ways.

All white panels (both sided and ends) had a return edge of 1 1/2 inches on the bottom horizontal, and vertical edges - the top edges also had a return, but offset by 1/2 inch which is overlapped by the roof.
All white panels are hinged to the bottom part using simple brass butt hinges. There is a rubber (like car door) edged strip attached to the bottom part, which is compressed when the white sides are raised.
At the top of the panels, the roof overlaps the white panel so there are no waterproofing issues, similarly when it is folded down the roof overlaps the bottom.
All the white panels (being hinged 1 1/2 inches inside the edge) fold inside when the caravan is folded down - this was all done by careful measurement, and I only ascertained it would work when I erected it for the first time!
Each of the white end panels merely fits inside a channel moulded into the roof. The erection procedure is a copy of the Portafold.

[Mitchelkitman]

Be nice to see how you outfitted the interior, too.

I have no interior picture - I'll take some and (try to) post them up. Basically a simple L shape for seating during the day, with 2 backrest which "fill in" the remaining space to create the sleeping area.

[Junkboy999]

... I'll take some and (try to) post them up. Basically a simple L shape
for seating during the day ...

Sound good, love to see the inside.

Maybe you can get one of your mates to help you raise and lower it, while you get some pictures of the
hinges area and how the corners come together. We love seeing pictures.

[mezmo]

- this was all done by careful measurement, and I only ascertained it would work when I erected it for the first time!

Isn't that always the way ? Ha. A great feeling of accomplishment when
it worked as planned, I'm sure.

Thanks for the narrative.

Since you're going to do some interior pics, pics like junkboy999 said
of its operation and fitting would be helpful to anyone else considering
a similar set-up.

Cheers,
Norm/mezmo

[mezmo]

deleted double post

[Mitchelkitman]

Just a quick note to add that the total weight (without cushions!) is 194kg (428lbs).
I'll try to take some interior photos to post soon.

[Mitchelkitman]

Be nice to see how you outfitted the interior, too.

I have no interior picture - I'll take some and (try to) post them up. Basically a simple L shape for seating during the day, with 2 backrest which "fill in" the remaining space to create the sleeping area.

Have taken some interior photos at the Newark Kit Car Show in U.K. last weekend, but I don't seem to be able to attach them to a note. I don't usually have problems with computers, but I just don't seem to have any luck with this site
Oh - I think I may have been sucessful??

[aggie79]

Successful picture posting and wonderful tiny travel trailer! Thank you for sharing your very unique build.