Back in October, I got my Harbor Freight folder, and assembled it. Here are a series of pics showing the assembly of the trailer, and my black paint job [everyone on TNTT very fortunately advised me that it would fade to pink in a short period of time if i left it red]. After full assembly and attachment of the spare tire and jack stand, I was all ready to use my 2004 PT Cruiser TV to make a run to the forest green big box store [Sutherland's] and purchase lumber and assorted building stuff!
A couple of days after I got supplies purchased and stored, [did not have time to start on build yet] a bunch of my TPS [trailer parts stuff!] arrived courtesy of the UPS man. Bought it all from Bottom Dollar Surplus on Ebay, and was very satisfied with the price and quality.
The first picture shows an Atwood electrical charge/converter panel, 48X22 window [with emergency release feature], 29x24 window, roof vent w/fan, water inlet, sink faucet w/shower head, battery shut off, rear hatch light, cabin ceiling light, & twin reading lights. Second pic shows 43x23 round top cargo door, two 38x30 cargo doors, 24x16 wall vent for AC condenser air intake [in front of doors]. Since it will be a 4x8 super simple [no front roof rake] I will only be using one of the 38x30 cargo doors, as I will be using the 43x23 for ingress/egress and the 38x30 as a galley hatch.
Finally, I got around to actually starting the build! Here the 3/8 plywood [roadside] bottom of the floor frame has been attached to peripheral 2x2s and given 2 coats of Rustoleum Undercoating.
Oh, and I guess a few photos of my "shop" would be in order. Here are photos of my radial arm saw, Delta table saw [close and long], stored lumber, and stored insulation.
I flipped over the floor frame, and began working on the top part. I used 2x4s laterally, and 1x2s longitudinally to connect together as a floor frame. The radial arm saw was invaluable in cutting all to correct lengths.
After finishing the frame, I flipped the floor frame back over to use a multiplicity of #8 decking screws to firmly secure the bottom to the internal frame. I then applied a number of coats of Sta Kool elastometric roof coating to all of the frame areas. Turns out that, later, I would have to remove the coating on the lateral bonding surface so that the walls would glue up properly
After completing work on the floor frame, I placed it back on the trailer in preparation for attaching it to the trailer with carriage bolts. Being done for the day, the whole project was rolled back into the garage. Oh, and note the neat trailer dolly from HF tools that I am using to roll the trailer around. Very handy and on sale for about 50 bucks!
Well, here it is another day, and it looks like time to start work on permanently [I hope!
] mounting the floor frame to the trailer. I'm using 3/8 carriage bolts, wide washers, and countersinking them so that they do not interfere with the installation of the 3/4 plywood floor later on down the road.After the bolt on job is complete, liberal amounts of Sta Kool are used to seal up the bolting areas.
Next, we start work on the walls! I will have my door on the driver's side, and a big window on the curb side. Yeah, I know, traditionally the door, if there's only one, goes on the curb side; but hey, that 's why we build CUSTOM trailers! Like Burger King, I can have it MY WAY!
The curb side wall will have a large 48 inch long window [a la Paul Arnold's Wanderlust, but on the curb side]. It will also have a cut out for an air conditioning vent in the lower rear quarter. The vent will allow cooling air to be drawn in by the A/C's condenser fan, and the condenser output will be channeled out the rear of the camper via a to be installed cargo door. Here, the outlines are made: [Note, all outlines are on the inside walls, items will actually be mounted from the other side.]
The driver's side wall will have an entrance door in front, and a small window toward the rear. Here, they are outlined and set for cut out:
Here, the actual cutouts of the driver's side wall are made, the items are test fitted, and the wall section stored away for future use:
Another day, another project on the trailer! Here I am getting ready to work on the starboard [curb] side wall as my friend Jim works at getting that Sta Kool off of the lateral bonding surfaces of the floor frame.
Here, the 48 inch window cutout is completed, and the window is test fitted. I am reserving the cut out of the A/C vent for another day, as I am not sure that I will want to use that specific vent. It is MUCH larger than needed, and I may go with something smaller.
Well, today is early Wednesday, 19 December. We've had good weather recently, but it's all suppose to go to Hades in a hand basket tonight, as a winter storm with heavy snow and high winds is forcast for all of eastern Kansas.
Will be spending the daylight hours today retrieving my Bronco 4WD from out at Lake Perry, and getting ready for lots of snow. Got the snowblower prepped yesterday afternoon with fresh gas, and am ready to rock. Hopefully I can get back on my build sometime this weekend, or at least by this time next week. 
on the ground from last night. Hope we might get a break in the weather this weekend [predicated, of course, on a null outcome with regard to the Mayan Apocalypse!]
