deans TD build

[dean_petley]

g day guys and girls i am looking at planing out my new tear drop

what i wont from this trailer is to

sleep two people (in comfort)

light weight

good storage ie water tank about 20lt and food storage ie 60 lt esky to keep the rum cool

also nothing to big the tow car inst that big or powerfull or even fitted with a tow bar yet

if any one thinks that thay might have a plan to fit this list dont befraid to let me know tomorow ill measure up a base size im happy to live with

[mudcrab]

Hello Dean

I'm in western Sydney and have almost finished my TD build.

Happy to answer any questions if you think I may be able to help

Nev

[rebapuck]

You have the end result figured out. Now you just have to get there. This is the place to be for that. Welcome.

[dean_petley]

Hello Dean

I'm in western Sydney and have almost finished my TD build.

Happy to answer any questions if you think I may be able to help

Nev

G day Nev im in west Sydney out colyton way and if you think you could be of any assistance please dont be shy

i thinking of making the walls and frame hoops lid and door out of aloy
the chassis will still be steel

1 to keep the weight down
2 because i work with the stuff all day building toolboxes and aloy trays for utes ect ect

tonight im just going to put pen to paper and work on a basic lay out of frame walls chassis

[dean_petley]

a rough section of the roof wall and hoop i am going through the extrusion book tomorrow to see what i can use to join and seal the roof and wall and to affix the sheet to the hoop i am thinking aloy 6mm rivets

[alaska teardrop]

Hi Dean,

Since my fabrication methods are similar to what you are proposing, I look forward to watching your progress.

Here is a link about building the Northern Lite Traveler the a may give you some ideas on building lightweight:

viewtopic.php?f=27&t=51991

Fred

[mudcrab]

Dean

I'm in 7 Hills

I sikaflexed 3 mm sign board onto my wooden frame and used standard caravan extrusion to seal the wall/ roof joint.

Very happy with the smooth look. Don't know how to add a pic or I could show you

My last job is to make the aluminum mudguards (using 3mm 5bar plate). Would you be able to recommend a business that could weld the corners for me

Nev

[dean_petley]

Hi Dean,

Since my fabrication methods are similar to what you are proposing, I look forward to watching your progress.

Here is a link about building the Northern Lite Traveler the a may give you some ideas on building lightweight:

viewtopic.php?f=27&t=51991

Fred

that is a very good read and is more or less the basic construction that i was tinking of i am going down a slightly different road with suspension im thinking leaves just because AUS is a big place with lot and LOT of nothing inbetween and a leaf set up is about as rugged as you can get and parts are easyer to get / make on the side of the road if it comes to that

[dean_petley]

Dean

I'm in 7 Hills

I sikaflexed 3 mm sign board onto my wooden frame and used standard caravan extrusion to seal the wall/ roof joint.

Very happy with the smooth look. Don't know how to add a pic or I could show you

My last job is to make the aluminum mudguards (using 3mm 5bar plate). Would you be able to recommend a business that could weld the corners for me

Nev

g day nev where did you get the standard caravan extrusion to seal the wall/ roof joint.?

and by 3mm 5 bar plate do you mean checker plate ?

and as far as welding it i can do that if your ever about weatherill park Penrith way ? ill take it to tafe you can have it back next week

[mudcrab]

Dean

Very kind offer re welding. Will contact you next week if my search round here turns up nothing

Got my doors hatch and cover strip from Hans Vans on the Central Coast (Hans was very helpful)

But I am sure you could get the cover strip from any caravan repair place such as Barnes on the Hume Hwy Lansvale

Cover strip comes in 5 m lengths with black or white plastic insert so a bit tricky to transport.

Got my durometer for hatch seal, struts, centreflex hinge and hardware from Naughtons in wetheral park.

They may be worth a try for the cover strip

Nev

[dean_petley]

Dean

Very kind offer re welding. Will contact you next week if my search round here turns up nothing

Got my doors hatch and cover strip from Hans Vans on the Central Coast (Hans was very helpful)

But I am sure you could get the cover strip from any caravan repair place such as Barnes on the Hume Hwy Lansvale

Cover strip comes in 5 m lengths with black or white plastic insert so a bit tricky to transport.

Got my durometer for hatch seal, struts, centreflex hinge and hardware from Naughtons in wetheral park.

They may be worth a try for the cover strip

Nev

Naughtons in wetheral park. i got a lot of stuff for work through them there just down the road

also actiion ally do a table profile in aloy that will do the trick i think for sealing the roof and side

[dean_petley]

ok i have crunch a few number and i have a chassis that i am happy with as far as dimentions

my panel van is about 1700mm wide 1600mm tall and about 4500mm long

so i thinking of making the chassis for the tear 1550mm wide and 3500mm long

i have alowwed 2000mm for sleeping as i an 1770mm tall so i have room for a pillow and 400mm for a galley and storage with some pull out draws used for counter space but ill work that out after i have the chassis and walls up see what looks good to the eye

but i dont know how to load up the file or how to turn it into a jpg or similar file for uploading

i have modified the profile of the grumman 2 this i have not drawn up just yet its all on paper i have deleted the rear lowest radius for more internal room and i have taken the 15 inches of flat roof out from the middle

[dean_petley]

ok kids it been a while i have been busy with work and family BUT
im back for an update

built the chassis from 50 x 75 x 1.6mm rhs with 30 x 30mm rhs

this was the basic layout on a bench at tafe



welded end section



goose neck tacked in place



first lot of floor spans tacked in place



end caps / strengthening plates for the goose neck



all together and on wheels



with some alloy sheeting in place



and thats about as far as i have gone my next job is to find someone who can roll the steel hoops for the side profile so i can weld them inplace then the spreders then sheet the body

but i am having real trouble finding someone who can roll the the profile i have drawn on autocad i think i might need to build a press and do it my self

[michaelrsydney]

Nice work Dean! Not the first time you used a welder eh?

I look forward to seeing the profile you choose to build. My concern with your plan to frame it in 25mm square tube is that you have very little cavity space for insulation, especially in the roof. Ideally you need a combination of bulk insulation (foam or such) and an aluminium reflective surface facing an airspace of at least 20mm.

If you still need to buy hinge or corner strip I think Aussieteardrops are discounting some parts. I got my hurricane hinge and strip from there, though the 4 meter corners needed cutting to size before it could be sent!

http://www.aussieteardrops.com/

Are both your old Holdens EH? Look great!

[Junkboy999]

Great looking frame. I’d say just go for it and make you own bender. It is hard to find a shop that will do “Piece Work” ( just or of two parts ) any more. They all want full drawn out planes bigger contracts.




home made tube bender
https://www.youtube.com/watch?v=RBWXQ0t5Mw8