1st time build, Suprise for the wife (9-10,wall panel added)

[BuildingForFun]

Ok. Before a month ago, I had no clue what a tear drop camper was.......or that they even existed. But to show and tell about this project I need to go back a few months before and start there.

My wife and I do a fair amount of out of state traveling to relatives and an annual visit to a out of state church camp. This is a 10 day camp, at which the majority of the ppl bring in there campers and RVs, there are a few dorm rooms which we stay in. So with this in mind, she started talking about a camper.......but with a Nissan Murano......I said "no, it wont pull a camper." Then my wife said " how about a Pop Up?" So we started looking off and on for a few months on Craigslist, and actually stopped and looked at one as well. They all were either nice and out of our price range....or in our price range....but, not what we were looking for, or wasnt nice enough........ Guess you get what you pay for......THEN........

I work at a trailer manufacturing and sales company. And one day one of our trailers that we sold, came in for some service, and what was on it......Hmmmmm......What is that........My.....I think I need to get a closer look at that.....the guy hauling them was so helpful.....showed me them, showed me pricing, even showed me in them..........WOW, What a Great New Discovery!!!

[BuildingForFun]

These are the first Tear Drop campers I saw in person.....

[BuildingForFun]

More of the Little Guy Tear Drops

[BuildingForFun]

They sure were nice......But a Pretty Penny to. But wait, before I was in sales, I was in Manufacturing Welding trailers, and.................... I bet I could build one of those to my specs and quite abit cheaper...... And it would be lite, Just what we were looking for, and also have to mention How Great Looking and Cool they are, My wife and I Love Vintage things from the 50's and 60's, especially automotive stuff....So this should be right down our alley......So shoot, I should give it a try.....if I fail, then it would be fun failing, but if it turns our great, How kool it will be.

My wife and I have been married 5 yrs this Sept. I have always enjoyed getting her suprises, and she loves trying to guess them and also getting them. She has never heard of a Tear Drop Camper either, However, I have told here I am going to make her a suprise that will Out Do all other previouse suprises, ( Mac Book Pro, Suprise birthday trip to Gatlinburg TN, Ect). And of course since she is female, She is very curious, and I feel certain that she will never guess her new suprise. Since she likes Old School things and has been wanting a lil camper, I feel certain that she will be in complete shock and love it the first time she sees it. Also I am excited about giving it to her.......... Man, its going to be a long-anxious couple months. So, All she knows is that she is Banned from the garage, and that im building her the suprise which will Out do all the other ones (which she says its impossible to Better her Mac Book and Gatlinburg trip, LITTLE DOES SHE KNOW.

So after looking through the brochure (photo 2), and looking online, (Wow, I was amazed) I found the shape I thought I wanted to model after. (Photo 1) I believe it is the Luxo Tear by WesthoffDesign.com

[BuildingForFun]

Soon after I found this Great Forum and started looking at the Build Journals. Now I have a hard time using and understanding computers, and even a hard time putting whats in my head on paper (Crude design photo below) . But after looking and looking at the builds, I started planning and started buying some supplys. I went to CokerTire.com and ordered a pair of White Wall Bias Ply Tires. Also a mini Fridge for the galley, And one of my favorites, a Mini Coke Fridge for inside the cabin area. After going to Home Depot With Lots of Lumber, Foam Insulation, A Table Saw, Jig Saw, Wood Glue, Screws, Ect, I came back to the house and started unloading into the unprepared garage. Also one other thing I decided to do after reading the ways on some of the build journals, I came up with a idea to do the underside with aluminum to completely seal it from the weather, instead of trying to do a spray or roll on weather proof material. I went to a local shop that builds Aluminum Dog Kennels, http://www.jacksoncreekmfg.com/ and got a roll of Aluminum that is used on top of Semi box van trailers. This will be my first layer, before the layer of wood.

[BuildingForFun]

More photos

[BuildingForFun]

Rough Drawing, using the top one as the profile shape. will be uploading more interior layout soon.

[BuildingForFun]

So after getting the supplies unloaded I decided it was time to dig the welding helmet back out and go to the business and build the frame. Now if you look at the drawing sketch you will see I decided to put a Deck on the Front of the trailer, and make it quite abit bigger that the Luxo Tear. I must say that I think the smaller they are, the cuter they are. But I decided that I wanted a bigger size for more room. The Trailer frame is 77 inches wide and 15.5 feet long. The tear drop camper portion will be approx 12 feet long, and it will have a 3.5 deck in the front for luggage, and I ride motorcycles, so I could put one on the deck if ever needed to.

I built the Main Frame and Cross Pieces out of a 1.5x1.5 inch Tubing that the wall thickness is 32nds of an inch. It is a stacked frame though, so this frame sits atop the portion that the axle hangers and tongue are part of, this lower frame is made out of 2.5x2.5 tubing with a 32nds of inch wall thickness as well. The Frame looks very big compared to alot of the frames that I have seen on this forum, but it is extremely lite, rigid and strong. I just used one of our 3,500lb. axles that we use on a 6x12 single axle trailer, However i am concerned about how big the springs on it is, and that it will make the teardrop bounce due to how stiff they are, I will probaly take 2 of the 4 leafs out per side.

Below are some photos before it was painted, sorry they are not clear.... I will upload more that are clearer, they are taken after it was painted.

[BuildingForFun]

More photos of Trailer frame pre paint.

[Starseeker]

This will be awesome!

[BuildingForFun]

Photos the day it was painted and hitched to the Nissan Murano to head home to the garage.

[BuildingForFun]

I tried clearing out the garage by taking the Nova out and putting it in a garage at work, and after I got the trailer home, I discovered that if the trailer was backed in, (which was my preferred way to park it in the garage) it was about 5 inches to long. So I had put the trailer in forward, so that I could put the tongue into a walk way. Even then the Garage door barely clear...............

[BuildingForFun]

More photos of Garage.

[KCStudly]

Nice Nova.

[BuildingForFun]

So last nite I Cut the aluminum for the bottom layer of the floor, cut and laid the first layer of 1/4 ply wood, cut the joist, and filled in with the foam insulation. Tonite I hope to get the top layer of 1/2 birch plywood cut and fit, then take it all apart, glue and screw it back together, then glue the aluminum to the bottom.

Also I need to hit Harbor Freight up for some wood clamps and tools, and mabe Home Depot for a router.

Time line of when project started.
Started talking about a camper Mid Spring 2014
First saw a Tear Drop Camper, started looking into and making plans...June 29th.
Ordered Wheels, Tires, Mini Fridge, Ect off line...July 7th.
Went to Jackson Creek Manufacturing and bought aluminum for floor bottom layer...July8th.
Went to Home Depot and bought wood, foam insulation, screws, table saw, jig saw, Ect...July 9th.
July the 14th through the 18th I was out of town on a business trip, but that Saturday I got in the shop and built the frame...July 19th.
Had the trailer frame painted and I brought it home, Also started sketching the wall profile...July 22nd.
Cut wall profile out...July 23rd.
Last nite, got a good start on floor...July24th.

This is my first real project out of wood, I grew up in a welding shop but, im kinda intimidated by wood work. SO PLEASE, ANY IMPUT OR ADVICE WILL BE GREATLY APPRECIATED. LET ME KNOW WHAT IM DOING WRONG OR WHAT I CAN DO TO IMPROVE.

I will upload some design sketches soon.

Also will upload some photos of the wall profile soon.

THANKS A MILLION, Caleb.