My Vistabule-a-like build

[ZachR]

Like many others, I really like the design of the Vistabule. Bert Taylor did a great job coming up with features that seem to really add to the teardrop camping experience. All the windows, the convertible bed, the storage layout and even the shape are all very well done. While the idea of coming up with something totally unique is appealing, I'm also all about "standing on the shoulders of giants". That's why I am starting with the Vistabule design and maybe adding a few of my own customizations.

I've procrastinated posting my build log, so this first post is going to be long (sorry) in order to catch up.

I started by ordering a ton of parts. I want to put everything into CAD and find that it's best to take measurements from the actual parts instead of relying on spec sheets:






Here's the CAD model coming together:



Then it was out to the shop to actually start the build.... I made paper templates on the laser cutter to help get all the metal pieces cut perfectly:




Then a bunch of welding:


Assembling the axles and temporarily attaching the wheels to make sure everything lined up:



Making the mounts for the water tanks and battery:



To prep for paint, I wanted to clean the scale. These really cool pads from 3M made the job go quickly:


First a coat of primer:


Then a coat of black Rustoleum:


Next, I started building the floor out of ACX plywood. I know the Vistabule used aluminum foot pans, but I made mine out of plywood. I also added hatches for easy access to the water tanks:




Then coated all the exposed underside with Henery's:



And that's where we are today. Next up will be CNC cutting the walls!

[aggie79]

That's one heck of a first post! Fantastic work and a great design.

Take care,
Tom

[Dirtclod]

Cant wait to see this thing come to life. Keep the Pics coming.

[dmdc411]

Kmnn nm mnmnnnnm kbb

Like many others, I really like the design of the Vistabule. Bert Taylor did a great job coming up with features that seem to really add to the teardrop camping experience. All the windows, the convertible bed, the storage layout and even the shape are all very well done. While the idea of coming up with something totally unique is appealing, I'm also all about "standing on the shoulders of giants". That's why I am starting with the Vistabule design and maybe adding a few of my own customizations.

I've procrastinated posting my build log, so this first post is going to be long (sorry) in order to catch up.

I started by ordering a ton of parts. I want to put everything into CAD and find that it's best to take measurements from the actual parts instead of relying on spec sheets:






Here's the CAD model coming together:



Then it was out to the shop to actually start the build.... I made paper templates on the laser cutter to help get all the metal pieces cut perfectly:




Then a bunch of welding:


Assembling the axles and temporarily attaching the wheels to make sure everything lined up:



Making the mounts for the water tanks and battery:



To prep for paint, I wanted to clean the scale. These really cool pads from 3M made the job go quickly:


First a coat of primer:


Then a coat of black Rustoleum:


Next, I started building the floor out of ACX plywood. I know the Vistabule used aluminum foot pans, but I made mine out of plywood. I also added hatches for easy access to the water tanks:




Then coated all the exposed underside with Henery's:



And that's where we are today. Next up will be CNC cutting the walls!

Jjk

Sent from my SAMSUNG-SM-G870A using Tapatalk

[ZachR]

A few lessons learned (for the future me, or someone else trying to build something similar):

1. Start with the desired galley counter top height (36" is the standard kitchen counter height) and work out from there. Since there is nothing else on the build that is really a fixed height.
2. Torsion axles with a upward offset would have made things much easier. I made a last minute change to a leaf spring axle (trying to save some money) and it raised the height by almost 3in. As built, I'm not sure I have sufficient axle travel clearance. If I hit a hard bump, my axles might bottom out against the frame. If this becomes an issue, I might notch my frame and weld on some reinforcement over the narrow area.
3. Do as much as you can to the trailer frame while it does have the axles on. Without the axles, the frame is WAY more manageable to flip and move. Flipping the frame is really nice when running wires, welding the underside, etc.
4. Put EVERYTHING in CAD. Sure, I could cobble together pieces without a solid plan, but it is WAY nicer to squeeze everything as tight/efficient as possible on the computer and know it will fit in real life then having to cut/re-cut parts to make them fit.
5. Make stuff reparable/accessible.


I spoke too soon on my last post... the next step wasn't to start CNC'ing, instead I spent time doing several tasks while I still had the frame upside-down. I mounted the tow cable junction box, drilled/countersunk a bunch of bolts to hold the loom+wires for the brakes+lights and mounted the leveling feet. Figured this would be much easier now instead climbing under the trailer later.





Then I remounted the axles, bolted on the floor-pans, installed the tongue wheel, placed the water tanks and battery.

[ZachR]

A couple coats of poly can even make douglas fir look halfway decent:


I'm just finalizing the last few details for the side walls. Unfortunately, my CNC router can only handle a 4'x8' sheet (I know, I know... Boo hoo, my CNC router is too small. Hats off to those who cut everything with a jig saw and sanding block). This means my walls will need to be cut in three pieces with 6" vertical lap/scarf joints. Unfortunately, one of those joints falls directly in the middle of the door opening. With the 6" lap and some extra reinforcement hidden in the ceiling structure, I think it will be good. I'm also using 3/4" MDO that will then get laminated with a 1/4" pre-finished birch for the inside. This approach is nice because the 1/4" birch can cover up all the electrical wiring channels and help strengthen each of the lap joints.


For the roof spars, I wanted something strong and straight, so I bought a 16'x9"x1-3/4" LVL (an engineered plywood beam). The plan is to chop the LVL into three pieces (the interior width of the trailer + 1") and then rip it into 1-3/4" x 1-3/4" ribs.


The ribs will sit in 1/4" deep slots routed into the side walls.


Double checking my math for the rib length: 1/4" slots in the MDO + the 1/4" (will use actual measurement) birch laminate, times two (one for each side of the trailer) = 1" + 58" (the interior dimension).

[ZachR]

I did a quick test cut to verify my roof rib pocket dimensions. The little half rounds around just clearance for the 1/4" endmill (so I don't have to chisel out the corners). They are hidden by the ceiling :


In preparation, I treated my CNC router to a fresh fly cut of its spoilboard:


Pressing go on cutting the the first of four sheets of expensive MDO. Fingers crossed that I didn't make some foolish error:


After about 45min of cutting (those long scarf joints take a while to cut with only a 1/4" tool), here's what I got:


I couldn't help myself from clamping the pieces to the trailer frame to get an idea of what it will look like:



Doh!!! Turns out that I DID make one foolish error... the shore power and water hook-ups go on the other side. Not a big deal to patch those holes as they get covered on both sides.

[ZachR]

It may be hard to tell what this is, but I picked up four sheets of 4'x10'x.040" anodized aluminum:

It wasn't cheap, but I think it's the best way to go... wish I could get 5x10's but no one around here stocks it.

The center section of each wall is a little trickier to machine than the outer two, since the center needs machining on both sides. Since I'm covering both sides of these walls (one side with aluminum, the other with pre-finished birch), I don't mind adding a couple extra holes to make my life easier. By adding some dowel pins right in the center of the sheet it allows me to flip the piece over and keep it registered to the same zero coordinates on my machine. Worked like a charm!



Next I glued them all together.

[ZachR]

I love it when UPS drops off a BIG box...

First item is this cool trim that locks two piece of 1/4" material together.

This will hopefully create a water tight seal around my windows.

Next up is my new super fancy low power refrigerator. According to my bench supply, it's only pulling 2.4amps!!!


I also got the pieces for wall number two cut out. Not posting an image since they are just a mirror of the first set. Hope to have them all glued up and attached to the trailer over the next 2-3 days.

[nothotdog]

I love it when UPS drops off a BIG box...

First item is this cool trim that locks two piece of 1/4" material together.

This will hopefully create a water tight seal around my windows.

Next up is my new super fancy low power refrigerator. According to my bench supply, it's only pulling 2.4amps!!!


I also got the pieces for wall number two cut out. Not posting an image since they are just a mirror of the first set. Hope to have them all glued up and attached to the trailer over the next 2-3 days.

NICE. Would you mind sharing the vendors & details on these last two items? I'm looking for both ATM for my build.

Jordan

[ZachR]

Hi Jordan:

Here are links to both... The window trim and the refridgerator

-Zach

[ZachR]

I pre-wired my walls to make sure I could get the needed wires into the slots. However, I may pull out the short pieces of wire and replace them with much longer runs, so I don't have a bunch of joints hidden inside the ceiling.


Once everything had wires run to it, I glued up the 1/4" pre-finished birch onto the MDO sides. I used a ton of 3/4" finish nails around the perimeter to hold it all together while the glue dried.


I also gooped up the bottom edge of the walls with the Henery's as an extra precaution. I'll have trim around the edge, but figured a little extra sealant couldn't hurt.

[ZachR]

Dry fitting the sides and the roof ribs... everything seems to fit as it should. It almost looks like a trailer!


I tried (and kinda failed) making a small "test" window to see how this trim-lok stuff works. It's much harder to use than it looks on the youtube videos. I think I need to get the "official tools and make sure my corner radii are large enough...

[ZachR]

My skeleton gets some skin:


Think I might punt on using the Trim-lok. It seems really difficult to use (or maybe I just don't know the tricks) and I worry that the thickness of my plastic isn't exactly .25", so it may leak. I think I've come up with a different plan of attack for the windows, so... more about that soon.

[ZachR]

I spent some time attaching the ceiling to the roof ribs and installed the extra ribs to support the fan:


I cut out the parts to build the storage cabinet that separates the sleeping quarters from the galley:


I assembled all the pieces:


And tested out the sliding doors:


Next up is going to be sanding and lacquer.
Lots of sanding and lacquer....