Flyin’ Gypsy - 6x10 vardo style Foamie build

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Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Sun Mar 06, 2022 11:45 pm

Well, I’ve asked (way to many!) noob questions, collected all the materials, had my utility trailer modified by a welder, and I’ve started my build.

As I’ve said before, I’m loosely basing the build on a vardo style Foamie I saw on the Facebook Foamie group:
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I plan to make a rounded front end on it similar the to FoamStream here on the forum to improve aerodynamics:
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Frankly, other than the overhang of the roof at the rear, it will probably look more like the FoamStream in the end, as mine will have straight sides, not sides flared outward as the vardo style Foamie above, and the front end will be rounded like the FoamStream, not a flat front like the vardo pictured.
Last edited by BrianInVA on Mon Apr 11, 2022 11:14 am, edited 4 times in total.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Sun Mar 06, 2022 11:54 pm

My utility trailer was an old flat bed 4x8:
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I wanted a 6x10 footprint so I had the tongue extended several feet and added some 3” box steel to the front of the trailer to extend the bed and tie it into the tongue.
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I found two used 2x10x20 pine boards I found on FB Marketplace cheap, and ripped them down to multiple 1 1/2”x3” pieces for my subframe. I bolted the subframe to the trailer frame with 8 lag bolts.
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Last edited by BrianInVA on Mon Mar 07, 2022 12:12 am, edited 1 time in total.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Mon Mar 07, 2022 12:03 am

I also found unused 3” Foamular 250 on FB Marketplace for only $1 more per 4x8 sheet than 2” xps at any of the local big box stores. (A contractor accidentally ordered two times as much of it as he needed for a refrigerated warehouse he was building. It was still wrapped on its original pallet.)
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I found a cheap old 25x75 RV door on Facebook Marketplace:
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And I’ll be using two single pane 14x21 shed windows, which seems to be the best combination of cheap, easy and quick for me:
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby GPW » Mon Mar 07, 2022 5:36 am

Just saying , now might be the time to coat that bottom wood with the Mix … :thinking: That will really help preserve it ….
Nice batch of foam … 8) :thumbsup:
There’s no place like Foam !
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Mon Mar 07, 2022 7:00 am

GPW wrote:Mix:

Ok, another n00b question - what mix? Link?

Edit to ad: Never mind, I found lots of explanations on the forum. I’ve been so concerned with xps and adhesives and pmf I never noticed all the references to “the mix.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Mon Mar 07, 2022 7:07 am

GPW wrote: Nice batch of foam … 8) :thumbsup:

Thanks. When I drew it out on graph paper, I calculated I needed 9 sheets, so when I picked up the xps I got three extra sheets, for the “oops” factor. Already I realize I hadn’t included the floor layer in my drawing. Hopefully I didn’t miss any other major parts in my calculations.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Mon Mar 07, 2022 9:13 am

As far as the name, I showed a friend this picture from the Facebook foamies group, and they said it looks like it could fly:
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Tue Mar 08, 2022 3:27 pm

I fitted the 3” xps between the subfloor frame and glued it in place with Great Stuff.
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I’m no carpenter. It’s not pretty, but it’s functional and sturdy.

I originally planned on using two 4x8 sheets of 3/4” plywood for the floor. But I couldn’t find any decent used plywood and new 3/4” sheets of plywood are $70 each now! I lucked out on some ebonized black tongue and groove 3/4” solid oak flooring someone had leftover from a remodel, for a LOT less. So that will go down next.
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My “delux” work space is a 10x20 China Freight car canopy.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby Spotman » Wed Mar 09, 2022 9:27 am

:D Brian, looking real good. I have a teardrop but thinking about the Vardos. Where in Virginia are you? I'm in Va. Beach. :thumbsup:
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Wed Mar 09, 2022 11:05 am

Spotman wrote::D Brian, looking real good. I have a teardrop but thinking about the Vardos. Where in Virginia are you? I'm in Va. Beach. :thumbsup:
Thanks.
I'm up in the northwest corner of Virginia, west of Winchester, about 14 miles from the West Virginia border.

I got the 3/4" ebonized black tongue and groove oak flooring cut and laid out last night. I'll glue it and screw it down Friday. (I can't believe I found this stuff, cheaper than basic grade plywood.)
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Tue Apr 05, 2022 12:18 pm

I finally got back to working on the camper trailer build. (I do some writing and had a deadline to meet for an article that required a lot of research.)

I got the 3/4” blackened oak tongue and groove flooring glued and screwed down to the wood frame and the edges planed even with the wood frame.

The 6” pieces of 3/4” oak flooring are each secured to the 1.5x3 wood frame with six 2” screws, and the wood frame is secured to the metal trailer frame with 8 bolts.

Yes, the oak flooring is overkill and adds weight. (Is it actually heavier than two 3/4” plywood sheets I had originally planned for the floor though? I’m honestly not sure). But I found it on FB Marketplace cheaper than two new sheets of plywood. Plus it just looks so much better than plywood.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby pchast » Tue Apr 05, 2022 8:39 pm

Have you made a weight target?
What can you tow with your current vehicle?
Do you need to budget part use for the weight of the
finished piece?
:thinking:
You are doing quite well with your finds. Better
than I could...
:thumbsup:
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby BrianInVA » Tue Apr 05, 2022 8:56 pm

pchast wrote:Have you made a weight target?
What can you tow with your current vehicle?
Do you need to budget part use for the weight of the
finished piece?
:thinking:
You are doing quite well with your finds. Better
than I could...
:thumbsup:

Thanks Pete.

I’m disabled from multiple strokes (I’m fairly good physically but have chronic post stroke fatigue and I just can’t stay awake for a continuous eight hour day) so I have lots of time on my hands to find bargains, and with the limited income that goes with full disability I have lots of incentive to find stuff cheap.

My Ford Crown Victoria is a small v8 but it’s rated towing capacity is only 1500lbs.

The original trailer was 340lbs. I added approximately 30lbs of steel at most when I had the tongue and bed lengthened.

I figure the 3/4” oak flooring is only marginally heavier than the two sheets of 3/4” plywood I had originally planned as a floor, which weigh 60lbs each. So I figure another 140lbs or so at most for the oak. The 1.5x3” framing might add another 60lbs, probably less.

I have 3” xps foam, so it’s probably 12lbs per sheet. Even if I use a dozen sheets, that’s only 140lbs.

Add on weight for the pmf. I have no idea how much that will add up to, but I doubt it could be more than another 100 lbs.

I’m sure I’m missing something, but I doubt the final build will be over 850lbs. That gives me plenty of margin for trailer contents.

I really doubt I’d add 650lbs in stuff inside. I don’t plan an elaborate interior. I have a large comfortable folding cot I’m going to use. I’ll have several five gallon spring water jugs with a hand pump for them, a collapsible sink, a non pressurized marine alcohol 2 burner stove for cooking and heat, a Luggable loo and a 12v cooler refrigerator. I’ll build a small kitchenette with xps and 1/8” plywood to house the water jug with pump, collapsible sink and 12v cooler, and stove. I’ll just use laundry baskets for clothing and other personal stuff that fits under the cot.

In 2019 I spent ten weeks driving from Maine, down to Tennessee, out Route 40 to southern California, up the west coast to Washington, then back east by way of Route 94 and Route 90, hitting all the big national parks out west I could fit in. That was in a GMC Safari cargo van, camping out and back in it, using most of the same equipment I’ll use for the interior of this camper. So I already know what’s essential and what is not really needed. Since I had the cot in the back, I could stop any time I needed to for a nap.

In June I’m going to head out from here in Virginia to Rocky Mountain, Yellowstone, Grand Teton, Glacier and Badlands National Parks. (Since I’m permanently disabled I have a lifetime pass into all the national parks for free, and 50% off their campgrounds.)

I’ll trailer the Foamie and take three or four weeks this time for the trip.
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby GPW » Wed Apr 06, 2022 5:33 am

Brian , you're doing Great !!! :thumbsup:
There’s no place like Foam !
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Re: Flyin’ Gypsy - 6x10 vardo style Foamie build

Postby Spotman » Wed Apr 06, 2022 6:44 am

Keep up the great work and continue your dreams. Safe travels.

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