"Phoenix" 5'x11' Build

[twisted lines]

Look's EZ from my house

[cjlangellier]

2021-06-28

I dry fit my hatch to ensure I didn’t endure any warping or shifting during the paneling phase. I did notice that the bottom of the hatch may have kicked out an 1/8” or so from the stress the plywood is under in the sharp radius of the hatch. All in all I don’t think it’s a major issue at this point. I’m extremely happy with the final profile of the trailer. It was rewarding to finally see my vision come to life. After mock up I filled the finish nail holes on the interior hatch panel and sanded the panel for finishing tomorrow. I then worked on the storage access for my headboard. I used the router to cut a 1/2” deep shelf in the 3/4” headboard top piece. I then trimmed the center piece out with a jigsaw and cleaned all the edges up with a chisel and then sandpaper. Next, I cut a 1/2” piece of plywood to fit the recess in the top panel and sanded it to the profile of my cutout. The corners may still need a little refining but I’m happy with how it turned out. I can now sand, finish and install all my headboard pieces.

It finally feels like the end may be in sight. I am picking up the aluminum siding tomorrow and will spend the next three nights epoxying the roof and filling any voids in the exterior surface in preparation for installing the aluminum this weekend!

[cjlangellier]

2021-07-02

No picture worthy updates but I've made some good progress the last two nights. I had to wait out some torrential downpours but after 5 straight days of rain I was able to coat the roof with CPES on Tuesday night. Last night I made up several batches of thickened epoxy and covered every screw head, staple hole, void, and crack in the plywood. Hopefully if the aluminum or trim ever does leak, I have enough protection to keep the water from doing any major damage. Tonight I am going to trim up the aluminum skins using my profile template in preparation for installation Saturday morning. I'm really excited to see the skins and roof go on so I can get this trailer weather tight!

[GarthB]

Looking great Cody! The aggressive profile has already got to be turning a lot of heads as it sits in the driveway. I’m excited to see it with the aluminum on it.

[cjlangellier]

Looking great Cody! The aggressive profile has already got to be turning a lot of heads as it sits in the driveway. I’m excited to see it with the aluminum on it.

Thanks Garth! We’re getting lots of very slow, curious walkers past the driveway. I’ve had a few neighbors I’ve never met stop to talk about the build. It’s definitely a conversation starter!

Today was a good day. I finished all the prep work for the aluminum and with the help of a friend we were able to get the walls and roof skinned today! I got all the windows doors root vent and general profile flush trimmed. I think I’ll be finding bits of aluminum in my hair for weeks. My curiosity got the better of me and I had to do one mock up with the doors and windows to see what it would look like when it’s finished. Tomorrow morning if things go well, I’m going to attempt to wrap the walls with vinyl. I won’t spoil the color until it’s on the trailer.

[kimberbuilds]

Had to get one daylight picture of the mock-up.

Hey, Cody! Your build is coming along nicely, but I had to go back and ask about this mock-up!

What wood is used here? And is that a joint between two pieces above the wheel? It looks like the grain pattern matches up, so I wasn't sure.

I am planning my build now, and I'm considering exposed wood sides. The grain of that wood looks lovely to me, which is why I'm wondering if it's something fancy, or just plain plywood. Thanks!!

[cjlangellier]

Hey, Cody! Your build is coming along nicely, but I had to go back and ask about this mock-up!

What wood is used here? And is that a joint between two pieces above the wheel? It looks like the grain pattern matches up, so I wasn't sure.

I am planning my build now, and I'm considering exposed wood sides. The grain of that wood looks lovely to me, which is why I'm wondering if it's something fancy, or just plain plywood. Thanks!!

This mock up was done with what would eventually be my template for cutting the walls. This is 1/4” ACX plywood. There is a joint there that was made using drywall tape filled with tightbond wood glue. I did eventually use 1/4” ACX as the outside skin of my trailer. The joint there was just a butt joint with glue applied to the seam. When i did the final seal coat on the trailer I applied thickened epoxy to the joint just to ensure a good seal.

If you are doing exposed sides I would spend a little extra and get a high quality plywood like Baltic Birch. You won’t regret spending a little extra in the long run.

[kimberbuilds]

If you are doing exposed sides I would spend a little extra and get a high quality plywood like Baltic Birch. You won’t regret spending a little extra in the long run.

Thanks for the info. Baltic Birch doesn't seem to have the deep grain texture that the ACX does though.

I have an aquarium stand that was skinned in ACX. I stained and polyurethaned it, and it came out so nice. I'd really like the same look on the side of a teardrop. Maybe there's another "grainy" wood I could use instead.

[tony.latham]

You've done a remarkable job. Was it a challenge to find aluminum 11' long?



Tony

[eLink]

Today was a good day. I finished all the prep work for the aluminum and with the help of a friend we were able to get the walls and roof skinned today! I got all the windows doors root vent and general profile flush trimmed. I think I’ll be finding bits of aluminum in my hair for weeks. My curiosity got the better of me and I had to do one mock up with the doors and windows to see what it would look like when it’s finished. Tomorrow morning if things go well, I’m going to attempt to wrap the walls with vinyl. I won’t spoil the color until it’s on the trailer.

Great work!
What kind of sealant did you use under the aluminum? And did it cure properly over the epoxy ply?
I've been debating whether it's really necessary to coat the plywood first on mine.

[cjlangellier]

You've done a remarkable job. Was it a challenge to find aluminum 11' long?



Tony

Thanks Tony! Yes, it was so difficult to find that I actually never did track any down! I had one supplier put an order in for 4x12 sheets only to call back and cancel my order 2 days later. I got the same story from just about everyone I called. Supply is low right now and demand for sheets over 10’ isn’t high enough for most suppliers to order a pallet from the mill. I lapped an 18” piece with a 4x10 sheet of aluminum. I used VHb tape on the lap joint. I wasn’t thrilled about the extra seam but it’s hardly noticeable looking from the front of the camper. I’m confident it will hold up since about 90% of cargo trailers are built this way now.

[cjlangellier]

Great work!
What kind of sealant did you use under the aluminum? And did it cure properly over the epoxy ply?
I've been debating whether it's really necessary to coat the plywood first on mine.

Thanks. I roughed up the epoxy with 60 grit sandpaper and used PL Premium around the perimeter of the sheets. I didn’t have any failures in the areas where I could tape the seam down will. I did have the middle of a panel pop up at my sunroof framing because that was the leading edge of the front radius of the trailer. I ended up clamping that part of the panel down to the framing and it setup well. Between the PL and the trim screwed down, it should be held in place pretty well.

I researched a lot of builds before mine and it seems like most of the factory builders don’t seal the plywood before skinning. I just wanted the extra insurance that if there ever was a leak it would hopefully do minimal damage before it’s caught.

[tony.latham]

...but it’s hardly noticeable...

That's for sure.

Tony

[cjlangellier]

2021-07-05

Had a good couple days of building progress. My birthday is the fourth so my wife asked what I wanted to do for the day. I told her I wanted to wrap the camper so we spent the first half of the day prepping then laying down the vinyl. I was definitely worried about getting the vinyl down without any bubbles or creases. My wife was an excellent helper and I think we did a fantastic job! It saved us $1200 that we were quoted to have it professionally done. We did relax and enjoy a cookout in the second half of the day. Today I installed the rock guard, skylight, vent fan, baggage door and passenger doors/lights/windows. I also got my hurricane hinge cut to size and installed on the cabin. I’m going to wait a day or to for the butyl tape to stop flowing then seal the vent skylight and screw holes with Trem Pro. Progress is coming quick now.

My wife ultimately picked the color though I have to say I’m pretty partial to it myself. It will be hard to miss thats for sure.

[Bezoar]

Looks good - a nice birthday present! I like the color.