Benroy style dutchie (campable)

[teddy]

Painted the axle, replaced the brake cables with shiny new red ones, checked all the bearings, repacked them, now im hoping i did it all correct, as ive never done something like this before.

[teddy]

Last saturday i had some time to place the axle back on the chassis, yay, it rolls again!



Yesterday evening i did some boring stuff, cleaning small bits and pieces, painting them etc. pieces ill never see again, but its easy to do now, and i might regret it later on if i didnt make them pretty.
This evening i took a big step and chopped 21 inches of the back of the chassis, no turning back now! But it looks like a TD frame now with the wheels at the rear! I also drilled the holes for the new position of the stands, about 20" forward, so the'll be at the front of the new deck, instead of somewhere in the middle. You can see the driversside mounted already, the other one lies on the front, where the tonguebox will be, the clamp marks the front of the deck.

[teddy]

Last week the floor arrived, 3/4" coated plywood, 10 x 5', we call it "betonplex" or concreteplex as you would say, usually used to build reusable concrete pouring moulds.



Today i cut it to size (woohoo, first sawdust!)



Marked and drilled all the holes to bolt it to the chassis,



and coating the sides and holes with CPES.

[teddy]

Finished early with a clients car this morning, and suddenly i had the whole afternoon off!

So i printed an mounted the profile,


trimmed it,


and i couldn't resist to see what i would look like. What do you think?

[KCStudly]

Looks great! I'm sure you wll find it very helpful to have done such careful planning right from the start. I have found it very useful on my build to be able to jump around and work on different things, while still knowing that everything will (should) fit when it comes together.

Good job.

[rebapuck]

Looks good to me. Keep us posted.

[dales133]

Looks like a great design.
I'm in the process of building mine but keep changing track on body design(just finishing s ranch building my trailer)
Couple of questions .How wide is yours overall and are you installing guards or are your wheels tucked under like a more traditional caravan.
And I'd love a copy of your side plan to have a look at and show the minister of war and finances for approval if it isn't to much hassle.
Keep up the good work! Cheers dale

[teddy]

Im not doing much work on the TD at the moment, time is scarse, just a bit of sanding here and there so the router will follow nice and straight, and buying parts and materials. So no huge updates at the moment.

Dales133,
I've posted a full scale PDF here for you
The with overall will be 192 cm (6' 4"), with of the body 150 cm (5 feet) Length overall about 410 cm (13' 5") and a bodylenght of 294 cm (9' 8")
The wheels will stay outside the body like in the picture, but a fender will be atached. The image in my first post i made in this thread is still quite acurate, except for the arc in the rear, which accounts for the extra 14 cm (6"). If you need other images or more info, don't hesitate to ask.

[dales133]

Thanks for the response! I'll check out your p do.
I just posted my trailer build pics today.. I'm excited [WHITE SMILING FACE]

[teddy]

Off to the store today, and got me some plywood for the interior sidewalls.

After a short fight involving a hammer i got my router to do as it's told, and presto!


(I needed the hammer to convince the routerbit it would fit in the collar made for 6 mil, as my bit had a 6.3 mil shaft)

[teddy]

Stickframing the other way around.



All out of clamps now, maybe ive got some time to continue next week, and get some more clamps. :-)

[teddy]

Woohoo, more clamps!



And 2 coats of CPES on ther interior side of the first wall.



It looks a lot better now, the woodgrain really shows, and its a lot warmer. But im wondering, do i need to varnish it? Its inside, so not really any sunlight.

[noseoil]

Hi Teddy, I'm curious about the thickness of the wall. What is the outside skin going to be & it looks like you will be using something like 20mm insulation? Total wall thickness? Thanks, tim

[teddy]

Hello Tim, Its going to be a total thickness of around 30 mm. 5,3 mm inside skin, 22 mm insulation and frame and on the outside 3,2 mm aluminium sandwich panel.

[teddy]

time for an update, it's been a while, but im still around, time was just a bit scarce lately.

I wasn't happy with my plan to bolt the stands directly to the floor, afraid it would sag sooner or later, so i made a beam to go underneath the floor and chassis, so most of the upwards force would be done to the chassis instead of the bolts holding the floor to it.


I routered the thickness of the chassis off the plywood, and made a channel in it to fit the lip of the chassis in.


While is was at it, chamfered the visible edge of the beam.


Fits like a glove, just temporary, i need shorter bolds and it needs a bit of sealant to prevent moisture and dirt getting stuck between the layers.


the first beam that did not fit too well ( the router bit slipped out of the collar, resulting in a way to deep cutout) turned in a stand so i could work at a much more comfortable height.


Then i made 2 fake wall pieces so i could make the roof spars exactly to length,


with this little setup i ensured every spar was exactly the same length.


I also build a styrofoam cutter for the insulation of the walls and roof.


and both sidewals are done, without all the mess you get when cutting foam with a knife.

Slowly but steady i'm getting there, although my timetable is quite messed up already, May is rapidly coming closer now, but as long as the frost keeps away from my part of the world i might make it. Anyway, happy hollidays everyone!