Superlegerra -ish 5x9 foamy - First Trip!

[Shar]

Jthompson, getting paint and glue on ourselves means that stuff is GETTING DONE.

And Lthomas, I ran into the very same problem with the fenders of my trailer. I used a small saw (and a steak knife) to carve out enough foam to fit the wall behind the fender. I also made the decision to use a separate piece of canvas for that little "wheel well" that was created. Don't know if it will work, but...here goes.

[lthomas987]

I know I've been silent for a while. I have been working though.

I got all the internal structure cut and fit. I cut channels in the 2" foam wall for 1" foam partitions for the wall between cabin and galley and a small headboard area. I am fairly certain that once covered in linen and paint it will be plenty strong. I've got that little bikedrop build all out of 1" foam and it's really stiff.

I cut an opening for my small window. This weekend I plan to build the wood frame to support the window from the inside and get that all test fit and such. Once I am sure I like how the small window fits I'll move on to the big one and cutting the door.

I'll try and pull the trailer out and get some photos this weekend.

[GPW]

Pictures will be much appreciated !!! Anxious to see what you’ve done !!!

[lthomas987]

The side view as it stands now. With all of the roof on and the small window cut. I'll cut the other window and the door once I figure out framing.

The window frame, going to cut out the space for this on the inside of the foam so it is flush with the interior wall and the RV window will screw through the foam and into this.

I'm going to use linen covered foam for the wall between the galley and the sleeping area, and for the headboard area. To facilitate this I cut grooves 3/4" deep in the foam walls. The dividers then pop into place.



This doesn't sag at all as soon as the vertical piece is in place.

[The Teardrop Nanny]

Hi Laura,
you were silent for a while, but know i know why....ready to try those windows. Good idea to start with the small one first and the move on to the larger. I also like the linen covering. Today at the fabric store I saw they have foamy kits of all types and shapes to make your own headboards, panels, wall groupings, etc. They were really neat kits with countless possibilities for decorating.
Got work done on my galley hatch.....I just got it repaired and put back on as it got blown off while parked lakeside at the Applegate Gathering in Oregon.
Note to self: even though the view is beautiful there, don't park on the end (last) slot of the camping area and leave open the hatch.

Keep up your progress, Laura, and thanks for updating us with photos. If you want to see what I've been doing for summer vacation, check out the video of the IRG 5.0 Event....it was a fun summer camp.
ttfn,
TDN
Joanie

[lthomas987]

Well I made that nice window frame and then I started cutting into the foam to inset it. And it was going pretty well. Then I got a helper for 5 minutes to try and hold the window on the outside so I could dry fit the frame on the inside... and Um... Apparently I cut it wrong. It won't with the inner trim ring on the window. It's too small. So I guess if you have to have an error small is better than big. I could have saved myself a lot of trouble if I had test fit it on the window before excitedly crawling in the trailer and working on foam removal.

Tonight I hope to rip down some more 2x4s into 1x2s so I can re-cut and re-glue the frame. THen I will have to cut out more foam on the inside of the trailer. But the solder gun cutter is still working great so I guess that won't be too dire. I might have to form it again to make it cut a bit deeper though. Or rip my 2x4s a bit thinner. But I think they're about as thin as I want to go, as I want the screws to have something to really grab into.

It's that or work on the summer sausage for Dad's birthday gift.


Joanie,
That video is great! Sorry about your hatch. Glad you got it fixed.

[lthomas987]

It has been a productive week. Both of my $5 Craigslist Windows are fit. With frames installed.

I am puppy sitting too.

Next up canvassing internal walls.

[pchast]

[lthomas987]

Well I realized internal canvasing would have to wait. I have been covering the foam I am using for headboards and bulkheads though.

I need to solve my door dilemma. Everyone has the door dilemma right? It's dominating my conversation at meal times, even my co-workers who don't care about the trailer are starting to form opinions and camps and there were new drawings on my whiteboard when I got back from lunch today and I don't even know who drew them. Like how am I building a door?
My loving partner said "Don't they sell those?"
I said "Uh.. yeah but they're expensive."
MLP says "Well it's only money and I want to go camping."

So now I am considering a prefabricated door. Has anybody put one like Frank Bear or similar sells in a foamy? How'd it go? Did you put in a wooden frame to support it?

I haven't yet decided...but it is a tempting fast way to cut many hours of construction time out of this process.

[GPW]

Laura, a door is NOT that difficult , just requires Careful measuring ... That’s all .. really !!! Measure twice, measure again , then cut ...

[eaglesdare]

if I had to do over I would certaintly consider a pre made door!

[Mary C]

OK take a one by two and put around the door opening. Engineering says the sides go in first. Now make another frame that will fit inside the door frame I screwed mine together in the corners. Now lay it down on top of a two inch foam. Now mark on the inside of the wood frame. Cut the foam out.glue the frame around the foam, next mark for the door handle, cut a square of wood and inlay it into the foam. Use lots of glue.. let dry and cover door in canvas. Make sure you leave at least a half inch between the door and frame before you cover it in canvas. I did not leave enough room for the canvas and glue I am having to sand my doors. If i did it again I would leave more room for the canvas. You can do it! I know it seems difficult but really it was easy. Order your hinges on line, stainless or aluminum. It took four days for delivery.

Mary C.

[Shar]

I think you will need a wooden frame no matter what sort of door you make- they tend to be heavier than the other parts of the wall. On my foamy, for example, the entire back wall weighed 20 lbs, and the door that I built for it also weighed 20 lbs. Not sure what a premade door would weigh.

I built my own for 2 reasons: a) to save money, and b) because I wanted something with character, that said, "handmade" rather than "factory". It took me about 2 days to build it, and another day to install it in the trailer.

That said, many people have used premade doors on their tears and loved them. So really it comes down to your choice.

[lthomas987]

I am currently leaning towards making mine. Using something very like Mary's method. But I will make my opening a size and shape that will allow me to buy a door if I am running out of time at the end of build season. I live in Minneapolis and drive a 13 year old diesel VW. I have to park it in the garage for winter. So that is my drop dead date for trailer completion

[lthomas987]

OK take a one by two and put around the door opening. Engineering says the sides go in first. Now make another frame that will fit inside the door frame I screwed mine together in the corners. Now lay it down on top of a two inch foam. Now mark on the inside of the wood frame. Cut the foam out.glue the frame around the foam, next mark for the door handle, cut a square of wood and inlay it into the foam. Use lots of glue.. let dry and cover door in canvas. Make sure you leave at least a half inch between the door and frame before you cover it in canvas. I did not leave enough room for the canvas and glue I am having to sand my doors. If i did it again I would leave more room for the canvas. You can do it! I know it seems difficult but really it was easy. Order your hinges on line, stainless or aluminum. It took four days for delivery.

Mary C.

Mary,

Which way did you orient your 1x2s?
What do you mean sides first?

For my window installation I made 1x2 frames and then used a hot wire to cut channels in the foam on the inside of the trailer that accepted the entire frame flush with the inside wall. So 3/4" deep and 1.5"wide more or less. There was a bit of space for the gorilla glue to fill in.

Then my salvaged rv windows fit in with the aluminum frame on the outside and screws go through them and then through an inch and a quarter of foam and into the wood.

Tomorrow I will try and get some good pictures up.