The Coddiwompler

[eLink]

I had originally intended to build my own 8x10 compartment doors. But finally decided ease my anxiety and bought some prefab 9x12 Challenger doors instead.
I re-routed the original cutout so the new door now just barely fits top to bottom.

[Bezoar]

I like the look the skylights give it! That will be nice to lay there and look at the stars.

[eLink]

I like the look the skylights give it! That will be nice to lay there and look at the stars.

Thanks! No doubt, the skylights are gonna be nice. I just worry about building it right, with smooth curves and weatherproof.
But I have a plan!

[eLink]

The skylight cutouts need to be just slightly smaller than the acrylic panel; about 1/8" overlap all around. Seemed like it would be easiest to cut the holes prior to installing the plywood sheathing. So I made this template with a jigsaw, aligned it to the panel and used an offset router bushing to cut the opening.

First panel glued and stapled!

[Capebuild]

I've seen your individual posts but I somehow missed your "Build Journal".... glad I found it. Just went through all your posts.
Your trailer is looking really great! Enjoyed seeing your progress.

John

[eLink]

I've seen your individual posts but I somehow missed your "Build Journal".... glad I found it. Just went through all your posts.
Your trailer is looking really great! Enjoyed seeing your progress.

John

Thanks John! I look forward to seeing more of yours as well!

[eLink]

Wow, more than a year since my last update! I guess I lost steam on this project, so there hasn't been much progress. But in the last month or so my motivation has returned!
Just to catch you all up, I think the last major milestone was completing the skin (a year ago!).

Pre-bending the curve...


This portion of plywood was threating to crack when I tried bending it dry. Soaking it did the trick!




Here's where it stands today basically. So far, just the tongue box has a coat of poly.


This Labor Day weekend I started cutting aluminum!
FYI, if you ever considered using cheapo Harbor Freight pneumatic metal shears, don't bother. I barely got it to snip more than 4 inches at a time! A jig saw works just fine.


Side walls rough-cut and dry-fit.

[Capebuild]

Hello elink!! I always wondered if you had ever finished. Good to see your progress. Looking really great. ......Nice bends on the ply!
John

[lfhoward]

That’s a fantastic trailer design! I think it looks really cool and retro, like it would be at home behind a 1940’s vehicle. Anyways, looks like the hardest things are behind you (not that waterproofing and interiors are easy, but it’s basically all built!) Will look forward to future posts.

[eLink]

I decided to add wood doorstops. My local hardwood shop will mill the parts for cheap...not much more than the price of the sheet of plywood these were cut from! Totally worth it.



Used Tony's method for locating the hinges. Worked out well!



Discovered that my cutouts were too big for my windows (shouldn't have trusted the dimensions and corner radius specified by the manufacturer). Oddly, the trim ring fit perfectly. To make sure the rubber seal has solid backing I glued in strips of balsa.



I finally decided it was time to throw my acrylic sheets in the oven so they can be bent to a 24" radius. It all went well until...Big surprise, just like Shrinky-dinks from the days of yore, they had shrunk by 1/4" all around!! Thankfully I have a local plastics shop that cut me some new ones while I waited (on a Saturday even!). The new ones fit perfectly!

[eLink]

Progress update... Skylights in!

[Capebuild]

Looks really great! Your skylights came out very well!! Nice!!

[Onajourney]

They look fantastic!!

[Onajourney]

They look fantastic!!

[eLink]

They look fantastic!!

Thank you!

Looks really great! Your skylights came out very well!! Nice!!

Thanks John,
I was encouraged to get them done after seeing how well they worked out on yours!