6x12 V CT Conversion

[Gettin Started]

Thanks to all on this forum for inspiration and ideas. I picked up my trailer last week and started the conversion this weekend.

I built two seats with hinged lids prior to the trailer's arrival (they'll double as a bed with middle section inserted) and folding bunk beds for the kids.





Over the weekend I inserted 1" foam insulation in the walls, ran 12V wiring for outlets and lighting, sealed up some cracks with spray foam, and added 2 exterior lights. I found that a table saw worked great for cutting the board insulation.



Next up is to insulate ceiling (1") and add headliner, add ceiling lighting, and insulate beneath floors (2"). I plan to put a freezer converted to fridge in the nose and once that arrives I'll build the base cabinet housing PD4045, all electrical connections, and 2 6V Costco Golf Cart batteries (enclosed box vented to the outside). Had a long time to plan while the trailer was on order so I have most of the parts (still end up making multiple trips to Home Depot for odds and ends).

Will post as I make progress. While I plan to build this out pretty quickly, any comments or feedback is appreciated.

[aggie79]

Very nice! I am looking forward to seeing your conversion. I hope to convert a CT some day myself.

[Gettin Started]

Finished interior insulation, ran 12V electrical behind the walls, 2 exterior 12V lights, and put the ceiling liner and two overhead lights in place.



Next up...paint walls and finish front cabinet so I can hook up electrical to the PD4045.

[makevx73]

Wow! Fast work.

Good luck!

[OP827]

You do a very quick work, nice!
Do you mind sharing more details/pics on how your folding chairs/bed works? Thanks!

[Gettin Started]

Had a long work week, but made a lot of progress this weekend.

30 amp service is in and running...also pictured is a vent for the battery box located in the front interior of the trailer



After numerous planning iterations, this is how i decided to store the batteries. Slides allow batteries (2 Costco golf cart) to pull most of the way out to check water level, box is air tight on the sides, top and bottom and pretty tight on the front. Box is also vented through the front wall of the trailer. I didn't want to worry about them being stolen if stored on the tongue, didn't want to remove them after each use, and I didn't see the trailer clearance allowing me to put them in a box below the floor. So this is it.



Placed bunk beds, and seats (w/ hinged storage) and completed wiring connections for the 12V and one 110 outlet (still have another 110 to wire). A middle section will be added to use the seats as a bed (5ft wide and 69" long). We're short so that will be livable. That is a chest freezer with refrigerator thermostat mounted on the wall above it. Will add an inverter to power while underway, but otherwise will use the 30 amp service when camping. My dorm-size fridge ate up way too much power...this setup will use far less and is way cheaper than buying a super high efficiency 12V fridge.



Close up of the front half. I have to add a countertop, and latch to the panel w/ electrical service since the tension on the 10-3 service wiring likes to push it open. After that, need to add insulation below the flooring and I'll be done.


Plan is to finish it up next weekend then get some camping in before the snow flies. Then take some time to add upper cabinets in the front. Oh yeah, need to get my stabilizer jacks mounted too. Will likely take it somewhere to get welded on.

[Gettin Started]

You do a very quick work, nice!
Do you mind sharing more details/pics on how your folding chairs/bed works? Thanks!

Bunk bed vertical posts are 2x8's, with a 1x8 across the top and two strips of approx 4 inch wide pieces of 3/4 inch plywood supporting horizontally where the bunks attach to the frame. I used 2 inch self tapping metal screws to secure the horizontal members to the wall and into the vertical studs.

I used the tutorial at the link below to guide maybe 90% of the build. I found the instructions on how to secure the bunks to the frame confusing, so I used 1/2 inch bolts as the hinges with washers, locking washer and nut on the end.

http://www.diynetwork.com/how-to/skills ... y-bunk-bed

Bunks are made entirely of 3/4 inch plywood. I used 4 inch wide strips for the sides and a 30 inch wide by 72 inch long piece for the bottom. You can size to meet the dimensions you desire. This is the other picture I have during the build but if there's anything specific you would like to see I can take more.

[Gettin Started]

The trailer is now campable, and I'll be doing so in 4 days. Installed 2 stabilizer jacks in the rear, 800 watt inverter that powers the fridge while underway, made the cabinet countertop, finished the insert between the seats to make the adult bed, added latches to the battery cabinet and electrical service cabinet, wired in the 2nd 110V outlet. Seat cushions arrived, which help made the trailer look less drab.

Have a few minor things to add for convenience, and hope to add the below-floor insulation tomorrow. Can't wait to camp later this week.

Bunks up


Bunks down

[starleen2]

nice setup!

[Rainier70]

Well done.

[Gettin Started]

Just returned from a 2 night trip and am really happy with how things turned out although of course there were a few lessons learned:

1) As we were departing Brake Controller showed a short so no trailer brakes on the way there...no big deal as we were climbing 3,000+ feet to get to the camp site. Thankfully that fault went away when I hooked up the trailer for our downhill return. Even though the trailer is only roughly 2K pounds, it was really nice having those brakes going down steep inclines. The trailer (and minivan tow vehicle) braked much more smoothly.

2) 800w inverter (1,000 watt peak) would routinely overload running a chest refrigerator that Kill-a-watt had shown to only draw 255W when starting up----unexpected. 6 ga cables only run 2-3 feet between batteries and inverter so that shouldn't be an issue. I only use the inverter to run the fridge while under tow and the campground was only an hour away so no big deal for this trip but looks like I'll have to upsize (and investigate whether pure sinewave would be any better).

3) lots of experience gained in what gear should be stowed where...will continue to fiddle with it. Half of the front cabinet storage is blocked when the bunks are folded down and seat storage isn't conveniently accessible when that area is being used for a bed...the inconveniences that come with making the most of a small space.

Few pics of the trailer at an awesome campsite.

[aggie79]

I really like the seating arrangement and bunk beds! Congratulations on a nice outing. That is a beautiful campsite.

[Gettin Started]

I've been making a lot of minor adjustments since completing most of the build. Just added a major addition, a 270W solar panel and MPPT charge controller. Also coated the roof with Henry's 587 roof coating.