GuyllFyre Alpha 2 - 5' Wide

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GuyllFyre Alpha 2 - 5' Wide

Postby GuyllFyre » Mon Feb 25, 2013 10:45 pm

So last year I attended this VW/Audi event.
http://www.40sinabag.com/
The people were awesome!
The show was wonderful.
I had a lot of fun but after drinking, I knew I needed to sleep before driving.
I slept in my car.
Needless to say, it sucked.

It's been a long time since I've posted here, have been doing many other things, also have some experimental teardrop stuff happening on the SOOPER SEECRIT!

Let's throw out all the secret stuff, currently doesn't apply. It will when I decide to make some money doing this but I've got other requirements that take priority.
I have to make a single season campable teardrop that fits on my trailer before May 4th. So here goes.
Teardrop 101, cheap, quick, and dirty.

The objective:
Fits on a 4x8 trailer.
Doesn't require massive bending skillz.
Quick build to be 1.5 season campable.
Basic storage.
Reasonably lightweight.
No fancy materials.

Caveats:
My converted 1956 boat trailer is in desparate need of an overhaul, so I'm investing a chunk of cash in the trailer itself as a 4x8 material hauler with new springs and tires along with some levelers to use it with the teardrop. The cost of the upgrades is nearly the cost of a new HF trailer but this gives me new 12" tires and a spare, wheel chocks, levelers, and a really sturdy 1956 steel chassis to work with rather than cheap Chinese c-channel and unknown bearings. This trailer has hauled boats to Canada and back for my grandfather, boats all over the Northeast of NY for my family, and hauled a LOT of materials around after being converted to a 4'x7.5' trailer. The axle is solid, no worries, so I figure the investment to straighten the frame, make it a full 8' long (adding 6"), add different leaf springs, lower it to be better towed by my car, and basically tune it up is well worth it.
$275.65

This has been hauling family stuff for years and will continue to do so, so figure some rust killer paint as well as probably another set of new lights and wiring.
$100 or so.

Materials:
4 Sheets of the cheapest 1/2" 4'x8' material I can find, may be 7/16" OSB...close enough. - $60 or so.
1 Sheet of 4'x8' FRP. - $35 - maybe?
10 of the cheapest 2"x3"x8' I can find. - $35 or thereabouts?
Cheap but new 9" roof vent - $21.50 - ordered.
120mm 12VDC Zahlman quiet fan - $9.16 - ordered.
Tubes of FRP glue/Liquid Nails. - $10 - maybe?
Screws, sheetrock, deck, anything cheap, recovered, salvaged, or otherwise. - Free
Gallon or two of exterior white oil based or other hard to destroy paint. - $40 or so?
Beg, borrow, steal, scrounge, salvage, anything that can be.... - Free
Random wiring and connectors are part of my life, I can't even enumerate the cost. I'm always buying, salvaging, or using wire of all sorts, plus crimp connectors, breakaway connectors, heat shrink tubing, high current connectors...it costs me money somewhere but I'm always using them, so I don't always remember that these things cost me $4, $8, $3, $10....

Going to enlist my little brother to help me re-weld the chassis and install the new springs.

So, I'm not really going to count the trailer as part of the project since it's a needed item (at least in my family, you can't do without one), but I'm going to attempt to keep a running tally of the trailer costs and mods, plus the the down and dirty teardrop construction costs.

The idea is to make a pretty basic profile. 4'x8' sheet of material, 2' radius on front, 4' radius on back.
Instead of a full hatch, I'm going to make a 2' tailgate for storage and leave the rest for inside shelves, as it will make for much simpler construction.

No idea how this will turn out. I have a vision in my head which is pretty accurate and will probably be the reality but the pictures will show whether or not it's practical.

This will probably be a horrible build thread, an ugly outcome, but if I can do this in a short time and have something to camp in for a night, it will be worth it for the experience and then allow me to move onto more complex builds and fun.

More than one of you have probably gone about this in the same fashion.

Enjoy watching your nightmares come to fruition. :)
Last edited by GuyllFyre on Tue Apr 29, 2014 7:02 pm, edited 3 times in total.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Mon Feb 25, 2013 11:26 pm

Exhibit #1
On the left you will see my 2001 Audi B5 A4 1.8T Quattro which will be the new tow vehicle.
I have the hitch and wiring on hand, it's just a matter of installation.
The right you will see the 1993 Audi 90 V6 Quattro which was the previous tow vehicle that I have sold, plus the 1956 chassis trailer.
Image
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby tearhead » Mon Feb 25, 2013 11:32 pm

Best wishes and congratulations for embarking on this challenge! I look forward to seeing what you come up with!
Pat from Wisconsin
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Mon Feb 25, 2013 11:54 pm

Trailer hitch and wiring is on hand.
Image

Also have another fun project that can go along with but may not happen in time for this.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Tue Feb 26, 2013 12:12 am

Consulting Manuel.
Image

1996-01 AUDI A4 SEDAN
1998-02 AUDI A4 & S4 AVANT WAGON & 00-02 S4 SEDAN & QUATTRO
11169 / 247303
8/3/2007
GROSS LOAD CAPACITY WHEN USED AS A WEIGHT CARRYING HITCH: 2000 LBS. TRAILER WEIGHT & 200 LBS. TONGUE WEIGHT.
***DO NOT EXCEED VEHICLE MANUFACTURER'S RECOMMENDED TOWING CAPACITY.***
Parts List
PART NUMBER
DESCRIPTION
3/8 - 16 x 1 1/4
HEX BOLT
ITEM QTY 2 8 3/8" FENDER WASHER
1 8
3 8 3/8-16 HEX FLANGE NUT
1
BODY LIP
REAR BODY PANEL
2
SPARE TIRE WELL
HITCH WEIGHT: 17 LBS.
3
INSTALL TIME: 30 MINUTES
INSTALL NOTES:
DESIGNED FOR USE WITH
BALLMOUNT #55001 / 45501
DRILLING REQUIRED
INSTALLATION STEPS
1) Apply a strip of tape to the surface of rear body panel to represent the bottom edge of bumper fascia.
This is used to assure receiver clears the bottom of bumper fascia when installed.
2) Temporarily remove complete rear bumper assembly. From inside trunk, remove two bolts per side
securing bumper to body. Remove screws retaining fascia at rear of wheel opening. Release fascia
from clips at side of car by pulling up and out. Some models require the bumper assembly to be pushed
forward on car 2-3" and pulling fascia outward. Bumper assembly will slide to rear.
3) Position hitch on center of vehicle and level the assembly. Based on application this hitch will mount
6 1/2" to 7 1/2" down from body lip. (Note: Check receiver height at tape mark for fascia clearance. Adjust
hitch position if necessary. Using hitch as a template, mark and drill holes for fasteners. Four in rear body
panel and four in tire well.
4) Install fasteners as shown then torque all 3/8" fasteners to 30 lb-ft .
(Note: Large fender washers go inside tire well.)
PERIODICALLY CHECK THIS RECEIVER HITCH TO ENSURE THAT ALL FASTENERS
ARE TIGHT AND THAT ALL STRUCTURAL COMPONENTS ARE SOUND.
Curt Manufacturing Inc., warrants this product to be free of defects in material and/or workmanship at the time of retail purchase by the original purchaser. If the product is found to be defective,
Curt Manufacturing Inc., may repair or replace the product, at their option, when the product is returned, prepaid, with proof of purchase. Alteration to, misuse of, or improper installation of
this product voids the warranty. Curt Manufacturing Inc.'s liability is limited to repair or replacement of products found to be defective, and specifically excludes liability for incidental or
consequential loss or damage.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Tue Feb 26, 2013 12:19 am

Manuel says Que?
Image

No matter, we'll get it installed.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby TRP » Thu Feb 28, 2013 12:17 pm

Ah yes, the ever confusing Curt Hitch manual. I simply consulted the oracle on this one; Google. ;)

Curt actually posts a ton of videos on youtube to 'eh splain the install of their hitches. The only thing they don't suggest is to trim of the excess length of the bolt and paint 'em black. I took a quick grinder pass on each bolt and blasted them, and the lower tire well with a quick pass of undercoating paint. Not necessary but it really cleans up the look of the rear of the vehicle. FWIW - my Tow Vehicle is a 2004 BMW 325i Wagon.

http://www.youtube.com/watch?v=NjzDONJ_YQ8

Ted
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Thu Feb 28, 2013 12:45 pm

They always make it look more difficult than it really is.
I've done enough trailer hitches to have no issues installing it but sometimes those diagrams, well, make one go, Que?
The undercoating is always a good idea. Audi does a great job on rustproofing but when you punch extra holes, it's best to follow up with sealant.

I'm hoping to get the trailer hitch installed this weekend and with any luck, go pick up materials, then bring the trailer over to my Dad's place where all the welders are.
With any luck, my shipment of spring parts will be here.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby jstrubberg » Thu Feb 28, 2013 3:36 pm

Guy;

You know that "other" project is siting there begging for an EVO conversion...

Good luck on the trailer.
The more stuff I take along, the more time I spend taking care of my stuff!
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Thu Feb 28, 2013 6:13 pm

EVO conversion?
It's already a modified moped, going to do some cowling additions and make it Tron Legacy-ish.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Fri Mar 01, 2013 7:13 pm

Parts started arriving today.
8AWG wiring for 12VDC umbilical cord, crimp connectors, 9" vent, 120mm 12VDC Zahlman quiet fan, 12" tires, stabilizers, wheel chocks, and springs and install kit!
Pictures, we all love pictures!
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Image
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Sat Mar 02, 2013 3:31 pm

Today I've been installing the trailer hitch.
Hitch went on pretty easily. Bumper cover decided to be a bit of a PITA to pull off but it came off.
Aligned hitch, drilled holes, mounted, and sprayed with undercoating.
Image
Image

Working on figuring out how to neatly install the light wiring.
The B4 90 had the luxury of spade connectors to plug the hitch wiring into, made it quick and simple.
No such luck with the B5A4.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Sun Mar 03, 2013 4:11 pm

So nice to have a hitch again.
I know some people don't like them but I missed having it.
Image

First load of materials to start the teardrop build.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby Woodbutcher » Sun Mar 03, 2013 5:08 pm

Looks like you are ready to get rolling. No going back now! Have fun, and enjoy the building process.
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Re: 40's in a Bag - Camping Needs - Cheap, quick, and dirty.

Postby GuyllFyre » Sun Mar 03, 2013 5:48 pm

What better place to work on the profile but the living room!
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