New build in Temple, TX

[TxDave]

I built my first non-traditional teardrop over a period of 5 months this past Summer and Fall. It was built on a Harbor Freight frame, and skinned with Filon. I had so much fun building it that I decided I needed to build another one. So, I listed it on my local Craigslist and sold it 3 hours later.

My first build.

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For my second teardrop project I decided to weld my own frame, and will skin the camper with prepainted aluminum. I will use lessons learned from the first build to make this one even better.

I welded the frame using my nifty Hobart Handler 140 mig welder. Its mostly 2x2 tubing with a couple of channel pieces.

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After cleaning the steel, I gave it a coat of Rustoleum Clean Metal primer then followed with Rustoleum glossy black. The whhels and tires are from etrailer.com.

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It took about 8 days to cut the steel, weld the parts, install the suspension, and paint the trailer.

I am by no means the skilled craftsman that so many people on this forum are, but maybe someone will find something interesting in my build. I will make an effort to post photo updates on a regular basis.

[TxDave]

I like to have small side projects for those days when I don't have a lot of time to spend working in the garage. Today, I worked on my galley counter top. I made a stainless steel sink for $15 using a $9 stainless steel mixing bowl from Target and a $6 drain from Lowe's. Surely was a lot cheaper than buying a real RV sink.

sink made from a stainless steel mixing bowl and a small wet bar type drain

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By the way, I didn't have much time to work on the trailer because I was out flying my scratch built Sonex. The weather was just too nice.

My scratch built Sonex airplane at the Temple, TX airport.

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[KCStudly]

#1 and trailer frame for #2 both look very nice.

Welcome to the forum.

Is there a build log for the plane? I'd be interested in learning more about that, and of course, am looking forward to following along on your 2nd TD build.

[Vedette]

Hi Dave
As an aircraft builder, I am sure you have given a lot of thought to the "structural strength" and "weight" of your new trailer chassis?
An I am also assuming from your previous builds, that you do your homework!
Thus, I would love it if you could share the material sizes and gauge used in your new build....plus chassis weight???
Thanks
Brian
PS Looking Great so far!

[TxDave]

Thanks for the kind words, KC. Here is a link to some photos from my aircraft build: http://1drv.ms/XAjqOW

You might enjoy this little video I made of me enjoying some flying time. http://youtu.be/AK-9Nn8rcLQ

Hey Brian. I used 2X2" tubing 1/8" thick. I also used some 2" channel (1/8" thick). The frame is probably way overbuilt. I did a whole lot of research right here on this forum before starting both campers. There are a lot of truly bright people posting here. The airplane building experience helps...but its not a teardrop.

Did a lot of work on my floor (deck) today. The bottom is 1/2 exterior grade ply. Frame is 2x2's, and the floor is 1/4" ply. The interior of the structure received 2 coats of Valspar exterior primer/paint combo, because I had a gallon sitting in my garage. I plan to use 2" of R-Tech foam insulation. This is a shot of the underside after receiving a coat of Black Jack Roof and Foundation Coating. Nasty stuff, but I may do a second coat because I'm a little OCD.

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Dave

[Vedette]

Very cool flight.......Thanks for the ride.
Where are the mountains???
And Thanks for the Chassis info. I have both .125 & .100 wall 2"x2" tubing available to me for my next build??
Miss Piggy is all .125 wall 2"x3" ........with 2"x2" outriggers on tongue. Way over built in my opinion, but I never worry at any speed or on any road??
BUT......I am trying to think "Lighter for my "Kermit" build??
Keep up the great work! You are progressing more quickly than most!
Good Roads
Brian & Sandi

[KCStudly]

Thanks for that. Nice job on the plane!

[kudzu]

Think I saw your trailer in a YouTube video last night when prowling around for something else. Looked great.

[TxDave]

Thanksgiving's over. Back to work on the trailer.

Hey Brian...there are no mountains anywhere near Temple, TX.

KC...thanks for the compliment on my airplane. It was a 5-year labor of love.

Kudza...I appreciate your compliment on my first trailer. Using that first one as a learning experience will make the current build easier.

After installing my deck, my next door neighbor provided me with some flooring leftover from a recent remodel of his living room. Its Wilson Art laminate. I think it looks pretty sharp...actually better than the flooring in my house.

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Next task was cutting the walls. I used a combination of my Rockwell Versacut (an amazing saw) and a jigsaw. Walls are 3/4 maple from my local Lowe's.

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With a little sanding the door and window frames fit nicely.

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Having fun!

Dave
My build..."The 6-week Wonder" viewtopic.php?f=50&t=61727

[AlgoDan]

Hey Dave your builds are great, and so is the plane. You sure have a plan and looks good.

[TxDave]

Thanks, Dan. Your build journal was very inspirational.

I made these jigs, which act as temporary spars, to hold the walls in position before adding the actual spars. They fit over the edges of the walls.

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We put the walls on temporarily to get an idea of our galley and cabin layout. I'm a visual learner. You can see my jigs in use.

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More to come...

Dave

[dales133]

Like the temp spar idea *stolen* thanks!

[Gunguy05]

I'm guessing after the metal work that went into that plane, that you could build the TD in our sleep

Looks great so far. You are gonna be done in no time.

Is this a keeper, or you gonna sell it too?

Brian

[tony.latham]

Scratch built Sonex? Now THAT was project. I'll be optimistic and guess 3 years. My EAA days are long past.

Anywho, you're drop is looking fine.

T

[TxDave]

Thanks guys. The Sonex took about 5 years to complete. Working full time as a Psych nurse got in the way of my hobbies.

Brian...I'm probably gonna keep this trailer for awhile, but will most likely end up selling it so I can build another one. This build will be skinned with red aluminum on the sides and brushed natural aluminum on the front and top. I'm thinking it'll look pretty cool.

Based on lessons learned from my first build, I'm building the roof/ceiling on my work table. I'll do the interior skin, wiring, and insulation, and then install the "prefab" roof as one piece. I feel its a lot easier to build this assembly on a flat horizontal surface. We'll see.

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