First Build: 5x8 Benroy-ish w/o galley (9/23 Cargo Door)

[ecna]

And so it begins...

Day 1 - 8/14/2012



After reading plenty of stories about how the trailer arrives, this one was in pretty good shape. Funny thing was that when they called to schedule the delivery they expected me to be home from 7:30am to 6:00pm to unload the trailer. That's wasn't possible so I asked if they could deliver it to a business in town for me and they agreed. Well, an 18-wheeler showed up at my house today. My wife was home and told them that it wasn't supposed to come to the house and that she couldn't unload it. The driver happily unloaded it. It actually worked out better as I didn't have to figure out how to get it home myself.

My 13 y/o son and I got right to work on it as soon as I came home. We ran out of light, but we're mostly done. It was a good night. It would be nice if they had someone who knew English sentences and not just English words write the instructions, but they were better than some others I've seen.



Even though there is a note in the box saying to make sure to find the Certificate of Origin, there was none to be found. I called NT and they said it comes in the mail as so often the boxes are destroyed. I guess that makes sense, but I was hoping to register the trailer right away and use that to pick up the wood. We're going away this weekend and the following weekend I'm taking the kids camping (in a tent!), so it might work out fine anyway.

The "build":

I'm really looking to get this done quickly. When I let a project go on too long, I tend not to finish them! We're really anxious to start using it. I'm starting with the Northern Tool 5x8 trailer above. It's basically a Rimple shape, but I'm going to use a different radius for the front and the rear to make it more Benroy-ish. I might stretch it a bit just to make sure I have adequate leg room, storage and bunk area. I'll be using solid 3/4 walls and a pre-made door. There will be no real galley area, so I'm not going to build a hatch. I'm going to use an RV take-off cargo door to get to a storage area. I'll be using a transverse bunk in the back for my daughter. Probably use 12v and 110 for some lights, fan and maybe a car-type DVD player.

That's it for now... wish me luck!

Eric

[CHUNKYMONKEY]

Good luck! I used 3/4 MDO, built on a 5/8 utility trailer. I stretched my sides 1 foot at the top and on the end. I will have a galley and hatch but left pletty for room for a queen size bed. I'm really glad i extended the headroom. I slotted the MDO with a router and splined it together. Titebond III was my glue of choice. With the help of your son, you should easily get that trailer to the campground soon! Can't wait to see photos of your progress.

Angela

[ecna]

Thanks Angela.

Parts are arriving... my Fantastic Fan, VIntek door and my Kreg jig are here.

I called NT and they won't / can't do anything about the Certificate of Origin. It "should" be here in a couple of weeks. We're going away for a few days, but when I get back I need to borrow a truck or something to get some wood. I don't want to lose 2-3 weeks waiting to register the trailer.

I'm still tweaking my ideas a bit and then I'll post them.

Hopefully... sawdust soon!

Eric

[treebeau]

Howdy,

You have a headstart on me but we are starting off on our own ventures about the same time. Funny thing is, I was typing my first post and hadn't even seen yours yet and my first sentence was "And so it begins." Saved it as a draft until I could figure out how to post pictures. Thenwhen I had that knowledge, I couldn't immediately see how to get the draft back, so I made a new post (and left off the "and so it begins" because by that time I saw yours).

Best of luck to you!!
Tim B.

[ecna]

Thanks Tim... you too!

[jbyrd]

Sawdust, Sawdust, Sawdust

[bc toys]

Great start and getting to do it with your son what great memories he will have . Good luck to both of you and keep pics coming

[ecna]

Finally... an update. Once the paperwork arrived from NT, I registered the trailer no problem. I was actually quite surprised how easy it was.

Day 2 - 9/1/2012

I headed off to a "premium" lumber yard about an hour away with the trailer to pick up plywood. The trailer cruised along great. At one point, I thought I lost it as I couldn't see it and I couldn't feel anything! I'm not sure I did the right thing for what I paid for this plywood. I went to Home Depot for a few odds and ends and I have to say for 1/3 to 1/2 the price, it didn't look very different. They did have 5x9 plywood for the floor which made things quite easy, so I'll try to focus on the positive of the trip. I was able to get the floor built. I used the Kreg jig... it was kinda fun! My overall length is going be 8' 8" so I'll be overhanging a bit. That's why you see the wider framing at the front and rear.



Day 3 - 9/2/2012

One coat of Hurculiner (a roll-on truck bed liner product) is on and I'm taking a break before the second coat. I'm hoping it dries enough today to insulate it, flip it over and bolt it on. I'd also like to finalize my profile. I'm on probably my 100th iteration of it. I'm just going to work it out in full scale!

[ecna]

I got the insulation done and flipped it over. The day got cut short due to rain... that wasn't supposed to come until tomorrow.

BTW, I really like the Hurculiner. I'm a litle concerned that if it works as well as they claim, I'm going to have black spots on me for quite some time though!

[campmaster-k]

Great start keep the pics coming!

[ecna]

Day 4 - 9/08/2012

I have never been so afraid to cut a piece a wood before!

The profile is now Benroy-ish. I stretched it to 8' 8" and I modified the radius as I needed a taller vertical section in the rear to accomodate the cargo door.

First wall cut...



Second wall cut, clamped together and ready for matching with the belt sander...



And the obligatory pose with my son...



Crazy day today. Tornado watch in NY! It's pouring, it's sunny, it's crazy humid. I like working outside better, but it looks like I'm stuck in the garage today. After a little break, I want to cut the hole for the door and then hopefully get some walls up!

Eric

[ecna]

Day 5 - 9/09/2012

A bit more progress today. Second wall is up along with some internal walls. The solid plywood at the front is probably odd, but I just felt like I wanted something solid there. A little bit... just cus, but I wanted some strength if we're sitting up against it and the way I want to finish the inside. It will still have regular spars and insulation on the outside of it, so I've only given up 1/2 or so of floor space and it makes me happy. Now that things are a little "smaller" to work on for a bit, I'm hoping that during the week, I can frame the vent fan, cargo door and add all the spars. It's not perfect, but I'm pretty happy with the way things are going.

[ecna]

Day 6 - 9/15/12

It's going a little slower than I thought it would, but it's all going well and I'm continually making progress. I was hoping to get this done in the evenings during the week, but it didn't happen. Most spars are in, just have to frame around the cargo door (hopefully today). I also haven't been able to find baltic birch locally to skin. I'm going to have to try a little harder as I'm about there.

[TRP]

Looking great so far.

What's the plan for the exterior? Aluminum? or Paint? Are you going to run more than one door?

You going to run Flowmasters on that thing?

Ted

[ecna]

Looking great so far.

What's the plan for the exterior? Aluminum? or Paint? Are you going to run more than one door?

You going to run Flowmasters on that thing?

Ted

Thanks for the comments Ted.

I'm planning on the one door. I know I'd like it better with two, but if I can live without it, I'd save $300. I might put a window in the other side to open up a bit, but haven't decided yet.

My plan is to treat it like a car (where I'm more comfortable)... I want to glass the whole thing, use some Bondo on some holes, filler primer and automotive paint. I hope it goes as well as it does in my head!

The Flows are for the '55 Buick you can catch glimpses of in the background... another project started, but not finished!

Eric