Was Foam Conestoga Now Stick Built Vardo

[razzer]

Darn , I hope you haven't given up on this idea cause it's so cool . It's really inspired me .

[depatty]

YEARS later.... Ended up finishing this one up as a Vardo and finally camping in it last month (Oct 2013). Still not completely done with it but life got in the way as it seems to have a bad habit of doing. Ended up using much more wood than I had planned on. Couldn't get the foam to bend the way I wanted on the roof but did use the conduit as the ribs. Will post some pix as soon as I figure out how to do so.

[GPW]

Dave, pictures Please !!!

[depatty]

Okay, here's some of the finished(???) or at least camp-able critter. Have got to get to the other computer to get the older pix of the build.



This was at about 4 miles from home into the first camping venture. Street side (dark) view. Stopped to check for bearing and tire heat and folks wanted to look at and in the Vardo or barn on wheels as one lady called it.



Same place with picture taken from the back. Door is off an old camper that I put on to make the trip. Am going to build a dutch style 2 section door to replace it as time allows.



And a curbside view, showing the dirty metal I used on the roof. Side wall is canvas over foam with wood battens to hold everything tight and add to the vardo look. Bamboo poles are supports for the tarp that attaches to a curved piece of conduit under the overhang. Steps are visible behind the door in their travel position.



And one of the messy inside. Bed is in couch mode. It pulls out at night and the futon unfolds to cover it. At the height I built it we've got around 75 inches from side to side. Pulls out to 52 inches. Closed about 32 inches. Table (in center) pulls out under it with a leg that drops down for support. Table seats have storage under them. Brown things hanging down on each side of the table are leather straps for pulling the bed out with. Gotta get the wax out and work on the movable slats.



Front view. Window is off of an old camper shell. Front wall is wood. Due to job changes and lack of funds to buy any more foam I ended up stick building most of the Vardo out of salvaged lumber so it ended up LOTS heaver than I had planned.



Here's the problem with this design - major drag. With the Tacoma as TV my fuel mileage went from 27 to just over 14. And any hill called for down shift and crawl. I'm thinking about trying a wing of some kind on the camper shell. Also looking at taking the metal off the roof and replacing it with painted canvas, both to save weight and get rid of the 2 inch overhang at the front.



But here's the good part. Camping on the bank of the Tennessee river 150 miles from home.

More details and pix of the build soon.

Later,
Dave

[GPW]

That is very Nice and the R-panel on the roof is really a cool idea !!! Strong stuff!!!

[depatty]

Got to digging around on the other computer and found a bunch of build pictures. As much wood is in this thing not sure it really fits in the Foamies category so if it needs to move will make another thread elsewhere.

Anyway, here's the build sequence up until the camera died.


In the beginning...


Front view of the trailer as I got it.


Warts and all.


Needs seals at the very least.


Deconstruction started.


Getting the fenders ready to paint.


My high tech portable tool bench.


Bottom edges of the fenders trimmed.


Closer look at the fenders.


First coat of paint on the fenders.


Little rough but lots better than they were.


A couple of coats later looking pretty good.


Raw materials.


And some longer raw materials. All recycled and saved from the dump.


And even more.


Shelter from the elements.


Getting started on the build.


Adding a bit of width.


From the front.


Restacked raw materials.


Inside view of attaching the side supports.


Taller shelter.


Front view of the ledges and sub flooring.


Well bolted and caulked.


Another inside view.


Hand cranked grinder that I use to keep things sharp.


Back view of sub floor.


One of the top emt bows getting used as a towel holder.


Plywood floor going in.


Floor in and seams sealed.


Front wall being test fitted.

Will continue in another post.

[depatty]

Ok, continuing the pictures from the previous post on the build.


More test fitting to get the side wall angles so the bed would fit crosswise.


Front wall going up.


Bed support test fitting.


Inside side walls going in.


More of the front wall up.


Front wall from the tongue.


Closeup of the front bed support. Recycled redwood 2x4.


Side wall.


Side wall stud.


Other wall going up.


2x12 chair. Much more comfortable than it looks.


Side wall as tall as it's gonna get.


More of the front wall done.


Starting on the back wall.


Another view of the back wall.


Front wall from the side.


Much further along.


Back wall mostly done.


View through the door.


Front wall with window in place.


Side wall waiting for foam.


EMT rafters with tarp covering.


Rafters other side.


And from the inside of the corner by the door.

Taking a supper break. Will post the rest of the construction pictures either later tonight or tomorrow.

[GPW]

Thanks Dave !!! love the pictures ... and who could forget that original trailer ...

[depatty]

Yea, it were ugly weren't it. And I know I reposted some of the pix but wanted to keep all of the build sequence together. Got a bunch more to post today that actually have some FOAM shown in them.

[GPW]

It were, but now it aint' !!! And that’s all re-cycled huh?

[depatty]

Was toward the end of this next batch of pix that my cam started acting up so there are some gaps and then no more of the build finish. But here they are FWIW...


Other corner by the door showing the temp workbench.


Back (door) end about finished. I think this is the first view of the scalloped facade boards. Each end facade board is made up of 4 pieces cut from a section of 1x6. Half lap joints between them. Scallops drawn with a compass and cut with a jigsaw. Was interesting getting the top (and bottom) curvature to match the ribs and ends. Used a pencil in a hole in a long 1x1 with a screw as a pivot to draw the arc. Same tool I used to get the arc and the top of the ends and form the ribs from. Harder to describe than to make.


A shot of the rear overhang showing the boards. They only span from the back wall to the facade board. Planed the tops and edges to they fit like a barrel. Don't think I have any pix of that part of the build.


Closer view right side.


And left side.


Overhang from the other side.


Overhang right.


Center.


And left.


Unfinished side.


Drivers side foam glued and clamped in place. Used 1x??? screwed into the studs to hold it while it dried. Glue was an adhesive caulk that I will NOT use again. Should have used GS or GG but hindsight is always 20-20 and all of that...


Next day cured with the 1x's off and seams caulked.


And from another angle.


Canvas going on. Painters drop cloth, cut along the seams. I stretched it dry, stapled the edges and under where the outer ribs were going and then slathered paint on the outside. Should have painted underneath first but its pretty well bonded and the ribs aren't going to let it go anywhere anyway.


Bottom edge trimmed off and about half painted.


Seal coat done. Really hardened it up.


Ribs and trim on drivers side.


And passengers side.


Closeup of the painted canvas.


Color coat going on.


About half way through.


Different angle.


First coat on.


Dried overnight.


Hitch view.


Closeup.


Trim going on.


Lotta caulking going on. And am very unhappy that I spent as much as I did on the crap Wally World stuff. Still have cracks everywhere I used it when the temp/humidity changes. Should have spent more and gotten a better grade caulk that would have shrunk and expanded with the wood.


Back about half caulked.


Inside. Sorry it's so dark.

And unless I find some more pix I have forgotten about that's it. I thought I had some of the roof foam, both inside and outside, going on but so far haven't found them.

Later,
Dave

[GPW]

Oh Yeah !!! That’s really NICE !!! Close up all the trim’s COOL... makes it look so "old school” Gypsy -ish’ ... Nice details ... Lots of Work there... Glad you included a modicum of foam ...

Dave, please update us as you continue !!! more too ...

[depatty]

Checking out the insulation on the vardo. Fired up a little 1500 watt electric heater at about 10:40 am. Below are some pictures from that time. Gonna see how long it takes to melt the snow on the roof which has 3 layers of 3/4 inch blueboard under the metal.



Note the little heater sitting on the table to the right of the door (little white blog )



Hitch end. About an inch of snow on the roof.



Bit closer view of the snow.



And a jug of water I had left inside. It was liquid about mid afternoon yesterday. Frozen solid this morning. WAY too COLD for central Alabama!

[GPW]

Dave , while it makes a really pretty picture of vardo in the snow (like a calendar pic) , it is a bit TOO COLD to be here down South ... All back to more normal by the weekend ...Thankfully !!!

[depatty]

Yep, I'd rather have see snow in pictures rather than on the ground and on my boots.

Local forecast calling for low 60's by Saturday then 50's and rain Sunday. Guess I'd rather have the rain than the snow though.