Collecting my thoughts: a 2nd build out of foam
Posted: Fri May 17, 2024 12:50 pmI think this is going to be a quasi-build log eventually. I am selling my 1st build to a good friend of mine a few towns over. That build was a "traditional" stick built squaredrop camper, ~5.5x8 on a harbor freight 4x8 trailer. The trailer frame was welded by me and my uncle back in like 2020.
Anyway, the great thing about a 2nd build is you can learn what you like and don't like from the 1st build. Here is generally what I am thinking:
Trailer frame:
At least 5x8 to start this time. I was thinking about doing a custom frame (my neighbor has a friend who does metal work full time, and I can get him to weld one up for me) but I'm unsure about how the axle would work on that - most of what I've seen online (aka etrailer.com) have the hub face to hub face width at 72". If I were to do a custom trailer it would probably be 6x9', with the intention of building an 80" wide x 120" long camper. (6.66 x 10').
Camper size:
I want to put the beds "sideways" from the traditional method. Why? I have a family of 4. Parents will sleep on the Queen mattress, kids will sleep in either custom build bunks, or a pre-build solution like the Disc-o-Bed frame. https://www.discobedshop.com/
Sidebar: why disc-o-bed? I like that it converts into a couch, I like the idea of modularity (AKA once the kids get older and get sick of camping with their parents
- we can remove the bunk beds and use it for something else w/ minimal effort). I also like the idea of taking it out and using it in the house if we had a lot of guests over. The downside is I'd have to modify the Disc-o-Bed frame to fit inside a 75" interior. Luckily, I looked into this somewhat, and it doesn't seem hard to do (hacksaw).... replacement bars for the disc-o-bed are cheap if I screw up. Don't tell their lawyers.
Anyway, back to size. Interior cabin size would be 75" wide and 116" long.
Wall thickness:
I think I want to use 2" foam to do the build with maybe a 1/8 luan / plywood skin on the inside to make it look nice. I would take that extra 1/4" into account when building the frame to ensure I still get my 75" of interior cabin width (hence the 80" I mentioned above... about 4.125" of walls per side)
Amenities:
No galley. I didn't miss it on my first build. I do want some storage which I will probably achieve by building a platform for the queen bed, to be level with the wheel wells; I just want to be able to slip in stuff like our camp stove, chairs, pop up canopy etc. It will probably be a shallow storage but should be able to fit a lot of that stuff. I'll have a wide cargo door on the outside back to get in/out of that storage compartment. Probably a few places inside for interior storage, but again, keeping that small - just need somewhere to put the phone/wallet/keys before bed.
Some basic electrical this time. I overthought the electrical system last time, and it turns out we don't use half of it on my 1st build. I'd like some 12V lights again, a few areas to charge a phone or other electronics, and I think that is it. If we have the option of shore power, I'll just do a 120V wall plug, bring an extension cord to connect to shore power, and mount an extension cord. To date, we have not used shore power! 12V really is sufficient for us. I would like to reserve the option to one day add a small TV with a digital antenna, it's always fun to tune into local news if we are near a metro area.
Shape:
To be determined still, thinking of doing a Rimple this time... I like the headroom from a squareback. Sketches are still WIP
Weight
My tow capacity is 2000 lbs on paper, but with passengers we can expect that to be more in line with 1400-1500 lbs all in (including gear), but, we must also consider I live in Colorado and my car has already struggled on some of the more aggressive mountain passes (Monarch pass specifically). I am trying to build this as light as possible. With the trailer frame at ~250lbs I'm hoping I can keep the rest of the build to under 200 lbs, for a dry weight of under 500lbs. I've been tracking things on a build spreadsheet and my rough estimate so far leads me to believe this is easily achievable with foam.
I will probably post more as it comes up... I've been reading this forum all the time just trying to get ideas.
Anyway, the great thing about a 2nd build is you can learn what you like and don't like from the 1st build. Here is generally what I am thinking:
Trailer frame:
At least 5x8 to start this time. I was thinking about doing a custom frame (my neighbor has a friend who does metal work full time, and I can get him to weld one up for me) but I'm unsure about how the axle would work on that - most of what I've seen online (aka etrailer.com) have the hub face to hub face width at 72". If I were to do a custom trailer it would probably be 6x9', with the intention of building an 80" wide x 120" long camper. (6.66 x 10').
Camper size:
I want to put the beds "sideways" from the traditional method. Why? I have a family of 4. Parents will sleep on the Queen mattress, kids will sleep in either custom build bunks, or a pre-build solution like the Disc-o-Bed frame. https://www.discobedshop.com/
Sidebar: why disc-o-bed? I like that it converts into a couch, I like the idea of modularity (AKA once the kids get older and get sick of camping with their parents
- we can remove the bunk beds and use it for something else w/ minimal effort). I also like the idea of taking it out and using it in the house if we had a lot of guests over. The downside is I'd have to modify the Disc-o-Bed frame to fit inside a 75" interior. Luckily, I looked into this somewhat, and it doesn't seem hard to do (hacksaw).... replacement bars for the disc-o-bed are cheap if I screw up. Don't tell their lawyers. Anyway, back to size. Interior cabin size would be 75" wide and 116" long.
Wall thickness:
I think I want to use 2" foam to do the build with maybe a 1/8 luan / plywood skin on the inside to make it look nice. I would take that extra 1/4" into account when building the frame to ensure I still get my 75" of interior cabin width (hence the 80" I mentioned above... about 4.125" of walls per side)
Amenities:
No galley. I didn't miss it on my first build. I do want some storage which I will probably achieve by building a platform for the queen bed, to be level with the wheel wells; I just want to be able to slip in stuff like our camp stove, chairs, pop up canopy etc. It will probably be a shallow storage but should be able to fit a lot of that stuff. I'll have a wide cargo door on the outside back to get in/out of that storage compartment. Probably a few places inside for interior storage, but again, keeping that small - just need somewhere to put the phone/wallet/keys before bed.
Some basic electrical this time. I overthought the electrical system last time, and it turns out we don't use half of it on my 1st build. I'd like some 12V lights again, a few areas to charge a phone or other electronics, and I think that is it. If we have the option of shore power, I'll just do a 120V wall plug, bring an extension cord to connect to shore power, and mount an extension cord. To date, we have not used shore power! 12V really is sufficient for us. I would like to reserve the option to one day add a small TV with a digital antenna, it's always fun to tune into local news if we are near a metro area.
Shape:
To be determined still, thinking of doing a Rimple this time... I like the headroom from a squareback. Sketches are still WIP
Weight
My tow capacity is 2000 lbs on paper, but with passengers we can expect that to be more in line with 1400-1500 lbs all in (including gear), but, we must also consider I live in Colorado and my car has already struggled on some of the more aggressive mountain passes (Monarch pass specifically). I am trying to build this as light as possible. With the trailer frame at ~250lbs I'm hoping I can keep the rest of the build to under 200 lbs, for a dry weight of under 500lbs. I've been tracking things on a build spreadsheet and my rough estimate so far leads me to believe this is easily achievable with foam.
I will probably post more as it comes up... I've been reading this forum all the time just trying to get ideas.
