New Off-Road SquareDrop

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New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 17, 2023 4:46 pm

Hello all,
I was a member back in the 2004-2009 days when @madjack, @irarat, @doug hodder, @AsianFlavor, and several others cruised these forums. I built my first teardrop back in 2005 my oldest son was 2.5 and my youngest was in the oven. I built a pretty little Camp-Inn Clone. After 4 years of pulling that little thing everywhere we simply out grew it. With a 4 yo and 7yo and two Great Danes we could no longer make it work. so we upsized to a 30' TT, Now that my boys are 20 and about to be 18 we no longer need the large TT. We traded in the 30' after 14 years of service and down sized to a 26' trailer. But all this time the little teardrop sat in the corner of our driveway and after a fight with a falling oak tree the teardrop did not weather very well. back in 2020 I ordered a Bronco and in 2021 I decided to rebuild the teardrop into an off road style camper to pull behind the Bronco. in hopes of finishing it before the Bronco made it, well that didn't happen but after some time off building to play with the Bronco I started the build again. This is what the Teardrop looked like days after I finished it, on its maiden voyage, and my youngest enjoying the top bunk I built, sorry not a lot of pictures, back in this day we used film in our cameras - I do have a lot of 4x6 pictures laying around. This is what the Teardrop looked like after the oak tree and years of neglect. And here is the frame being sanded fenders welded on and then shot with Raptor liner.

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Lil Zeus
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Wed Oct 18, 2023 2:57 pm

cut out the profile and took it out to get a look at it on the frame. that kid is the same one in the bunk in the last post.
getting the floors and walls mounted. the floor is epoxy coated and Raptor Liner on the under side. all wall joints are held together with 1x1 square dowels glued and S.S. screws from the inside and epoxy filleted. this when together really easy not bad for the first weekend.
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Edit: some information about the trailer frame: it is 2x2x1/8 angle, with a Dexter 3500lb torsion axel. the frame has been boxed to mount the axel and tongue jack. I decided to mount the fenders to the frame so they can be stood on in a pinch, the fenders are rounded trailer fenders I got from Tractor Supply. I did have to add a few supports across the frame to help support the fenders. My older son did most of this welding, he wanted to learn how to do it, I think he did really well for his first time. Now I have all kinds of stuff welded at the house. :lol:
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Lil Zeus
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 24, 2023 4:38 pm

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added spares for the roof all spares are joined with pocket holes. Started the Galley and test fit the hatch. the hatch is a food truck awning from RecPro
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 24, 2023 4:42 pm

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installing the interior cabinets and building the countertops for the galley, I will be adding a sink in that corner.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 24, 2023 4:50 pm

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Installed the inner 1/4" cherry plywood the cherry was only a few bucks more than the Luan so I upgraded a little.
Added foam (Garage door insulation) to the top and started to skin the outside. I framed out a location for a fan and added wiring for the fan and lights.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 24, 2023 4:58 pm

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built shelving for the galley. test fitted the hatch again.
redesigned the galley counter top to remove the sink, I will add a removable table off the side of the trailer for the sink. added a large access for storage.
Added the electrical to the front headboard outlets and to the Air conditioner that will go in the large hole.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 24, 2023 5:03 pm

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After tons of sanding it was time to apply the Fiberglass cloth and wet it out with epoxy.
during breaks in the sanding I found time to get some new wheels and tires and raise the suspension to clear the 29" rubber, and to give me a little more head room. I did have to replace the rear hatch struts with ones that had a longer stroke to open the hatch past 90 degrees to allow a little extra head room.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Tue Oct 24, 2023 5:08 pm

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Added several coats of epoxy, FYI 115 degrees in the garage only allows you about 5-8 minutes of working time. there were a few days I started working at 4:15 am to try and beat the heat. I am applying epoxy inside and out on all surfaces. I find that it doesn't leave a smell once it cures and I can add second/third coats sooner than spar varnish.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Fri Oct 27, 2023 3:19 pm

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After days/weeks of sanding and recoating with epoxy it is time to wire up the galley install the battery, and wire the shore power. finally laid some color with a grey primer.
laid several coats of Shercryl paint, installed the door trim and porch lights then installed the doors.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Fri Oct 27, 2023 3:25 pm

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Installed the tail lights Marker and Lic lights, installed the shore power housing. galley lights wired and working. Galley Mostly done, still needs some sanding and a final coat of epoxy waiting for some cooler weather. Even got and inspection and approval from the little dog.
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Re: New Off-Road SquareDrop

Postby Lil Zeus » Fri Oct 27, 2023 3:34 pm

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Air Conditioner installed, and interior lights wired and working. Took Zeus out for a trial run. Put about 50 miles on him Pulls super easy Only know he's back there an the larger bumps.
I did find that the tires came filled with 70psi and that makes for a very bumpy ride lowered the pressure to 35psi and it smoothed out nicely. Now to build the roof rack, 270 batwing awning and the solar shower and we will be ready to take him to Big Bend in December. also need to add Graphics to match the Broncos Everglades graphic.
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Re: New Off-Road SquareDrop

Postby S. Heisley » Fri Oct 27, 2023 5:25 pm

Congrats! It looks really good. :thumbsup:
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