building Plan B....

...ask your questions in the appropriate forums BUT document your build here...preferably in a single thread...dates for updates, are appreciated....

building Plan B....

Postby mike_c » Tue Dec 27, 2011 4:50 pm

Hi all--

Kathy and I do a lot of boonies camping, especially in the southwestern deserts. We also prefer to camp when we go on road trips, but as we've gotten older we've become impatient with the daily cycle of waking up, cooking breakfast, breaking camp (even if that just means folding up the sleeping bags in the back of the truck and repacking the gear back in), driving all day, then hauling everything back out-- you get the idea, I'm sure.

So the first appeal of a teardrop was the notion of hauling a ready made bed behind us, with making/breaking camp reduced to as few essentials as possible. But we didn't want to sacrifice access to roadless wilderness in favor of comfort, either. A light, sturdy, high clearance teardrop trailer sounded like just the project for last summer.

What was I thinking?

As I type this, it's just after Christmas, 2011, and this summer's project is still FAR from finished! But we're making incremental progress, and let's face it, we both have jobs that demand lots of our time. And I seriously underestimated the time it would take us to complete this project, but then again, we're having to learn whole new sets of skills as we go. And locate parts and materials. So it's been slower going than I'd hoped.

We're building a nearly 5 ft (56") by 10 foot teardrop loosely based on Kevin Hauser's Comet design. We're making a lot of it up as we go.

We began in July, 2011. First, I made some sawhorses. Then two work benches. We put up a portable carport in the back yard for shade, and I began welding up the frame from 2 x 2 x 0.120 steel. Well, first I welded up a BUNCH of small practice pieces of tubing, then I started on the trailer chassis once I was reasonably confident, LOL. I'll tell you what, most of the welds-- especially the early ones on the main rectangle-- were welded once, ground down, then welded again, just to make sure.

Just look at those spankin' new sawhorses!

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Moving out off the deck, with brand new running gear.

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Axle and hubs installed:

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I added receivers in all four corners for accessories, as well as a rear receiver.

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Ahhh..., summer.

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Priming the frame. Kathy and I struggled mightily to turn this thing over and over while welding it until I figured out how to use the rear receiver and the tongue to pivot it. On blocks, it rolls over easily. Physics-- it's a wonderful thing. We're also beginning to realize it won't be finished by winter, hence the second portable carport.

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The side wings will hold extra fuel and water cans. You can also see the leveling jacks in this pic.

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The completed frame, sitting on its wheels! Ruh-roh-- sides are up on the carports. Summer must be officially over in northern California!

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Thanks for looking! Stay tuned for more!

--Mike C.
If it isn't broke, perhaps a more expensive tool is required to break it....
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Postby Woodbutcher » Tue Dec 27, 2011 5:01 pm

Great looking frame Mike. It looks big. What are you planning to make? Standy, teardrop or something different? It will be fun to follow your progress. Have fun and enjoy yourself. For mr building was half the fun!
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update #1

Postby mike_c » Tue Dec 27, 2011 5:05 pm

Started a new post just because the last one was already so long.

Framing the deck on another sunny late summer day:

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Getting ready to cut the decking.

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The deck is bolted down here, so that means the black gooey stuff has already been spread on the bottom:

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The most essential element of a teardrop trailer, it's profile! We had to stretch the eight foot sheets of half inch ACX to ten feet:

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Thanks for watching us build it. Stay tuned for more!

--Mike C.
If it isn't broke, perhaps a more expensive tool is required to break it....
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update #2

Postby mike_c » Tue Dec 27, 2011 5:22 pm

Sides on the trailer, framing the rear bulkhead:

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Furring the inner walls. You can see most of the whole profile in this pic, although the wood grain trailer walls don't stand out from the brown carport background well, and the support posts cut off the front and rear. With the sides down, the double carport workshop just barely works, since it has to do double duty for tool and materials storage, too. It's becoming an art form working in there-- moving things around to accommodate tasks, then moving them again to perform another. GAWD I wish I had a big, heated indoor shop!

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Photographic angles will be somewhat limited until spring....

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Pulling wires:

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Insulating with 3/4 foam:

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And bringing us up to date in the last week of December, 2011, we applied the cabin inner wall skins. We're using plain blonde baltic birch for interior brightness, especially as we want to use indirect lighting for most interior use.

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Next, I'll begin work on the cabin cabinets. We're using cherry and maple for the cabin cabinetry! Thanks for watching and stay tuned for more!

--Mike C.
Last edited by mike_c on Tue Dec 27, 2011 5:59 pm, edited 1 time in total.
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Postby mike_c » Tue Dec 27, 2011 5:32 pm

Woodbutcher wrote:Great looking frame Mike. It looks big. What are you planning to make? Standy, teardrop or something different? It will be fun to follow your progress. Have fun and enjoy yourself. For mr building was half the fun!


It's a teardrop, roughly 5 x 10 (actually 56 in wide to accommodate a 54 in full sized mattress). It's been great fun so far!

--Mike C.
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Postby parnold » Tue Dec 27, 2011 6:50 pm

Looking very good Mike! :thumbsup:
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Postby starleen2 » Tue Dec 27, 2011 9:23 pm

Good progress so far :thumbsup:
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Postby aggie79 » Wed Dec 28, 2011 10:20 am

Very nice Mike! :applause: :thumbsup: :applause:

What a wonderful profile!

Your trailer came out great. I wanted to do as you did - learning to weld - on my teardrop frame, but didn't. Now you've given me motivation to try this on my second build.

Take care,
Tom
Tom (& Linda)
For build info on our former Silver Beatle teardrop:
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Postby mike_c » Wed Dec 28, 2011 4:45 pm

aggie79 wrote:Very nice Mike! :applause: :thumbsup: :applause:

What a wonderful profile!

Your trailer came out great. I wanted to do as you did - learning to weld - on my teardrop frame, but didn't. Now you've given me motivation to try this on my second build.

Take care,
Tom


Honestly, learning to weld the frame members and lay out the running gear probably added a month to my schedule, between acquiring the tools and materials, practicing welding, and then doing everything VERY carefully and deliberately. But in return I've learned a new skill that I've already used to repair some tools around the house, and I've been able to fabricate little things for the trailer like the battery box mount, and so on. Definitely worth the extra time and effort, I think. Plus I'm already thinking about ways to streamline a second build, LOL. These little trailers are FUN to build!

--Mike C.
If it isn't broke, perhaps a more expensive tool is required to break it....
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a non-update....

Postby mike_c » Wed Dec 28, 2011 4:49 pm

Not much progress during the last couple of days-- it's been raining steadily. Not really enough to make the shop unworkable, but enough to make some spots muddy and encourage me to address some different, less messy indoor chores, LOL. But they're TEDIOUS compared to building!

Later this afternoon or tomorrow I hope to finish skinning the rear bulkhead and begin work on the rear cabinets though. Keeping my fingers crossed for moderate weather....

--Mike C.
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progress is made....

Postby mike_c » Mon Jan 02, 2012 6:47 pm

OK, we've made some great progress this weekend. First, we finished framing the rear bulkhead (some of the backing is missing from this shot:

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Then we skinned the rear bulkhead (partially) and installed the spars. Now it's beginning to look like a teardrop trailer!

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Framing the vent fan opening:

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Alcohol and power tools with the safety guards removed! What could POSSIBLY go wrong?!

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Spars are installed! We used 3/4 x 1.5 inch poplar for the spars.

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We fitted the ceiling sheets of 1/8 inch birch ply. Although the sheets are square, installing them square proved to be a challenge, as the light gap in the upper right corner shows. I think the side skins are not quite flat, and the slight high spots snag the ceiling skins and drag them a little out of square. But the horizontal ceiling joints are straight and tight, so I'm not concerned. A little quarter round molding covers a multitude of sins!

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Now it REALLY looks like a trailer!

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And finally, 8) :

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We've also bought some nice teardroppy looking LED porch lights and nine 12v LED warm white puck lights to use for interior lighting. I'm going to make indirect fixtures to wash light across the light colored birch ceiling.

Yay, progress!

Thanks for watching and stay tuned for more!

--Mike C.
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Postby S. Heisley » Mon Jan 02, 2012 8:55 pm

You said it....: Great Progress! :thumbsup: :applause:
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Postby jabrobbins » Mon Jan 02, 2012 9:15 pm

That's looking great! Your doing it the right way from the inside out and incorporating the wiring from the start. I've really struggled finishing the inside after the outside. Looks like another great Humboldt build! We are really growing in numbers. Hope to meet you at IRG 4.0.
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building cabinets....

Postby mike_c » Mon Jan 09, 2012 12:54 pm

Not much to update today, really. I'll upload some pics this evening if I get a chance. I'm building cabin cabinets, and the pace of cabinetry is just slower than that of carpentry, I guess. Measure, think about it, measure again, think some more, measure again, dither around for a bit, have a cup of coffee, measure again, cut something out, test fit it, shave a hair more off the cut, fit it again, repeat, then set the piece aside and start thinking about another one. That's pretty much how cabinetry goes for me. I would not be Employee of the Month in a production cabinet shop. No indeed.

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Postby rand_98201 » Mon Jan 09, 2012 8:46 pm

I agree cabinetry is not a fun build wether it be for a kitchen or a TD.Youre coming along reallynicely though.When I do my build I would like to have some higher clearance as well.
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