Aussie Modernaire style build.

[captainkynan]

Hi everybody.
I introduced myself a while back but in any case I'm in Australia,the capital in fact and its pretty damn cold here.
Mid winter and regularly below freezing. Makes it uncomfortable in the shed.
I've been around for a while designing and learning. I have actually begun building and thought it was about time I shared.
I'm hoping the images are going to show up.

This is my profile. I have done some extensive CAD work over the past couple of years resolving issues and whatnot.
I hope no one gets too annoyed with metric measurements, I will endeavor to convert, if I remember.



Here is the trailer with the extended draw-bar. I think it was about 600mm (2'). made of 50x50x5mm (2x2x0.2") RHS and attached to the first two cross members and the triangular bracket.
I have shimmed the Hitch to fit the smaller tube.



The next two shots are of the rear stabilisers. I had to make a small bracket out of some angle.





I think that'll do for now.
I have uploaded a few other images to my album and will post them here and describe what's going on over the next few days.

[mallymal]

Love you swoopy shape. I'm struggling read your dimensions on the drawing.... Is that 1191mm? (we like metric in the uk but I think that's about 47"). Great for cutting out of a 8x4 sheet, but your title says 5x8.... Just checking something hasn't slipped ...

[captainkynan]

Oh 5x8 is the trailer dimensions.
The overall dimensions of the teardrop are L3000xH1200xW1550.

[mallymal]

Dohhhh. Good luck with the build

[captainkynan]

Good morning.
The trailer is an 8x5 bolt together trailer from Easy Trailer. I think they are manufactured by the same Chinese company that make HF and such 'Long Chih Ind.
It was about $950 delivered and went together very easily.

Here we are starting on the floor frame.
My design is a removable tear with 4 forward storage boxes and sunken cooler boxes in the galley.
I made a jig and routed out the joints.
The eye bolts you can see are where the attaching bolts locate from the floor.


The cage hanging down near the center is where one of the two batteries will go.


Almost done with the floor frame.
Not all of the eye bolts will stay. There will be 8 in total and there will be an image of the attachment later.


Here's the boy screwing in 140 screws.


Battery cage. I made it with some old pool fencing we had lying around.


I made this dowel rig to check that the depth of the boxes wasn't going to cause any clearance issues.
It is a series of dowel hung under the trailer. I drove around the suburb, up and over as many speed bumps as I could. No issues.


Sub Floor done. The floor is 9mm structural pl. Not very pretty, BC grade i think, but it comes up quite nice.


Underside of the floor.
The four unpainted sections at the front are for the storage boxes. The two either side of the battery were going to be for the bower distribution. A series of issues had me shift them to the back.


The front section gets a roll pan.


Starting on the boxes. Lots of screws and glue hold them in.


The cables here are for running lights and 12 Volt charge from the TV.


This box goes in the back and houses two 22L Eskys (coolers) on the outside and power distribution in the center.


Floor with the esky at home.


I put LED light strips in the boxes hooked up through micro switches. When the ls is removed the light comes on.



I have about 4 tins of stain and varnish that I had lying about. The ply came out OK.


And the clear coated box lids


I'll leave it there for now.
Please keep in mind that this is not a fast paced build. I am posting my back log of progress from about October 2012.
I'm not in a huge rush...

[captainkynan]

Back again.
I put some elastic straps in to hold the esky in place.
I took one of the screws out of the esky and put in a longer one with a large head and a spacer to catch the elastic.


Front roll pan.



I painted it with some black goo. will probably cover it with some checker plate at some point.


This is one of the mounting points for the camper.
A bolt through the floor goes through the eye-bolt.


A large washer and a wing nut.


I made a cardboard mockup of the profile.
This was before I added the draw bar extension.


I'd like to add that I am so grateful to 2Bits for his excellent 'Luxury Tear' build Journal.
It was a great read and got me going in a big way.
Thanks.

[captainkynan]

Next I'll try and detail the power system.

[captainkynan]

This is in the galley.
Esky and main power distribution.


A bit of a mess of wires.
The blue cylinder is a 24 connection cam switch it allows me to switch between the following.


3 Selections

1
240V AC power in.
Shore power connected 240V.
Converter running for 12V DC.
Battery charger connected.

2
All off.

3
12V DC
Inverter connected 240V.
Solar charger on.
Batter connected 12V DC

There is a fan that vents out. I put a 35C thermo switch on it so as soon as it gets hot the fan kicks in.
There is also a light connected to a micro switch that comes on when the lid is up.
Oh, and a fuse panel.
And ground Bus.
Magnetic latch to hold the lid down.
Shore power and solar come in at the back of the trailer.
The converter is a computer power supply. We'll see how it goes.

[captainkynan]

I've got plans for two remote systems.
This is the 4 Ch system. Here are the actuators for the central locking system
I had to make a switching circuit with a couple of relays.


Ch1 Lock
Ch2 Unlock
Ch3 Porch lights (These will be momentary switch to light the way for a wee in the night.
Ch4 ?

The other will be another 12 channel system to operate Lights, galley and stuff.

[KCStudly]

Nice work!

Do you have a baffle or shrouded deflector under the cabinet fan to keep water spray and road mist from spritzing up into your components?

I am including a positive vent fan blowing from under the floor up a chase behind the galley bulkhead to just above the mattress at foot height. This will hopefully: (1) positively pressurize the cabin and galley in an effort to keep trail dust out, and (2) act as a low noise cabin vent to promote cross flow and supplement the roof fan when less air is desired. Once I cut the hole thru the floor I plan to put a small 5x5 furnace type filter and filter gauze in the chase to keep bugs and dust out, and a 4 sided shroud under the floor with only the back open to cover the hole.

[captainkynan]

ImageUploadedByTapatalk1405820278.326026.jpg (28.94 KiB) Viewed 1528 times

I have a larger one of these vent covers under the box. Maybe it would be a good idea to put some kind of filter in there.

[captainkynan]

The box lids sit on these. The microswitch turns the lights on and off.



Light on.


Light off...

[captainkynan]

I got the frame up. This was a magic moment, one of the mile stones where I finally get to see what it's going to look like.
I printed the top sections you can see in the plans, glued them to 30mm thick pine, cut it on a bandsaw, finished on a disk sander.




Starting to assemble the frame




Here's my door. 900x600mm (35x23")


Frame up, it's a beautiful thing.