The Bondo Condo

[ADK]

This will be my second attempt at a trailer build. My first one, called the NAT (Not a Tear) did not get very far due to some Life changing events. My second attempt, The Bondo Condo, will be based on a 1950's type home built trailer that I found in good condition for $200.00. I'm going to use it as an adventure type trailer incorporating an RTT and tailgate kitchen. I do not weld or work much with metal so my medium of choice for the platform I will build is wood. I will be utilizing a truss type design sort of in the aircraft style for my trusses and a rigid foam insulated platform. Now I had to figure out the mounting system. I'm going to use the stake pockets in the bed as a starting point and after taking a few measurements I came up with these:

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Four end pieces, one for each corner and six intermediate pieces to run along the top of the bed. All of these will be attached to a top rail

[celticquetzel]

I have an idea yours will be an interesting build. Can't wait to see what develops.

[CarlLaFong]

I have to admit, I'm completely bewildered. Bed? Stake pockets? Is this a trailer or truck camper? What is an RTT?

[ADK]

After I made up the stakes I simply glued them to a side rail with T3 & screws.

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Since the trailer is currently being stored off site I made a quick trip for some dry fitting

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I ran a 3/4" dado down the side of some 1x4 for my side rails.

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My next step was to design & build the trusses that will hold the RTT. I do not use CAD so I "stubby penciled some designs and finally settled on something that was different, almost Steam Punk but I'm thinking kind of Aero. Now to move from the paper to the 3d.

[ADK]

I have to admit, I'm completely bewildered. Bed? Stake pockets? Is this a trailer or truck camper? What is an RTT?

RTT is a Roof Top Tent, popular with the Off-road community. Although I do own a Jeep I'm not an off road enthusiast but my trailer will be built in that style; with a few twists.

[CarlLaFong]

Aha! I see!

[jim littiken]

Cool idea, It has to be hard with the trailer not at your shop.

[ADK]

I completed the first of five trusses that will support my RTT platform. I drew full a full sized pattern and worked from that. the trim is made up of 3/4" square stock that I milled up in my shop and the "beam" portion is 1/4" exterior grade plywood. there are 14 pieces of trim that go on each truss.

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The bottom corners of each truss get a special piece of trim that I made up using my forstner bits and bandsaw, 24 of these:

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[ADK]

Cool idea, It has to be hard with the trailer not at your shop.

Just a temporary issue Jim, I'll be registering the trailer probably next week. I am going to have the tongue extended a bit and replace the old "screw down" type coupler with a Bulldog. Then the usual's; lights, wheels/tires, wheel bearings. Those are my August projects.

[working on it]

Cool idea, It has to be hard with the trailer not at your shop.

Just a temporary issue Jim....

I hope that it is just a temporary issue; my TTT was 50+ miles away at my friend's shop for 13.5 months. The initial build-up (frame re-sizing-welding, wheels/hubs, cutting the profile, building the exterior box) was a job best done with his help (I don't weld). His expertise in chassis building makes me sure that nothing is going to fall off! But, the internal workings, features, layouts (trial and error), and the modifications to be done were best left to me on my own. And on my own turf. So, after 14 months away, as soon as I had the doors and hatch mounted, I towed it home. My garage is crowded (and un-heated and un-airconditioned- as opposed to his shop), my tools are primitive, my supplies are what-have-you, I have no help (wife doesn't come to the garage much). The best thing is that I can work on it at every opportunity available, at home. I may have gone overboard on "unsupervised" work and design features (some that my "pro" friend advised against: i.e internal A/C, permanently mounted), but I had a vision before I even started building. Due to some difficulties, I finished last month (far longer a build than I had hoped for), but had to re-vise some things for better balance and functionality (tongue weight was too light, battery was dying). I should be finished again today. There is no substitute for being able to work on it on a daily (not weekly, or monthly- for as little as an hour at a time) basis, even if it is without aid or equipment. A little every day! 22 months and done (I hope). Good luck on yours.

[ADK]

Cool idea, It has to be hard with the trailer not at your shop.

Just a temporary issue Jim....

I hope that it is just a temporary issue; my TTT was 50+ miles away at my friend's shop for 13.5 months. The initial build-up (frame re-sizing-welding, wheels/hubs, cutting the profile, building the exterior box) was a job best done with his help (I don't weld). His expertise in chassis building makes me sure that nothing is going to fall off! But, the internal workings, features, layouts (trial and error), and the modifications to be done were best left to me on my own. And on my own turf. So, after 14 months away, as soon as I had the doors and hatch mounted, I towed it home. My garage is crowded (and un-heated and un-airconditioned- as opposed to his shop), my tools are primitive, my supplies are what-have-you, I have no help (wife doesn't come to the garage much). The best thing is that I can work on it at every opportunity available, at home. I may have gone overboard on "unsupervised" work and design features (some that my "pro" friend advised against: i.e internal A/C, permanently mounted), but I had a vision before I even started building. Due to some difficulties, I finished last month (far longer a build than I had hoped for), but had to re-vise some things for better balance and functionality (tongue weight was too light, battery was dying). I should be finished again today. There is no substitute for being able to work on it on a daily (not weekly, or monthly- for as little as an hour at a time) basis, even if it is without aid or equipment. A little every day! 22 months and done (I hope). Good luck on yours.

Thanks Working on it; The trailer is only a few miles away and at this point I am almost ready to start bringing it into town to work on it, unfortunately I cannot keep it in town since my shop is right in the middle of the city. I managed to complete almost all of the platform work in my shop and the tailgate kitchen will be built there as well. Since I am semi-retired I actually get to spend more time on it than most folks here on the forum do. I am still confident that I will be able to do some shake down trips late summer /early fall.

[ADK]

Now that I have built my first truss I have learned what not to do, that being said I laid out my template for the next four trusses. I cut four pieces of 1/4" plywood to 8x55 and used screws to tie them all together so now I have a 1x8x55 piece of plywood. The pattern was drawn on the top piece and all the pilot holes for the "holes" were drilled then I went over to the band saw and cut out the shape and came up with four rough cut trusses. After cutting out all the holes I have my "beams" or splines ready for trim.

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Next up was to mill up some 3/4" square stock: lots of it!!

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A couple of days worth of gluing & screwing and I'm almost ready for some dry fitting.

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[KCStudly]

Nice design on those trusses. They look nifty!

[ADK]

I have all the pieces of the framework essentially done and ready to dry fit them on the trailer.

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Now I can take all of this back to my shop and assemble it. The next step in this process is making the platform for the RTT which will be 3/4" pine, 1/8" masonite for the bottom, rigid foam and 1/4" plywood for the "top" or floor.

[ADK]

I have the beginnings of the framing for the RTT platform. I started with some 1x2 pine and half-lapped all the joints then I glued in all the corner braces.

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I made up some round mounting plates out of 1x pine and screwed and glued with T3 to the trusses.

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Later on I will drill through the platform and plates and fasten the platform with carriage bolts.

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I now have the rear half of the RTT frame done and ready for rigid foam and covering.