Mark's Weekender-XL build

[Gold5one]

I have made only moderate progress since my last post. I'm about 90% done with all the framing, and I am waiting for only one more window. Today I visited Lowes again and as usual I investigated the plywood bunks- probably the 10th time in a month. I hit the mother load of perfect plywood. 3/8" CDX that was either knot free on one side or had only one small knot- less than a 1/2", and tight. I bought six sheets, one after the other was like that as I pulled them off the pile. That will be enough for the exterior and I already had one sheet at home. They told me it will be a long time before foam board insulation (made from oil) comes down in price, even though oil has dropped by over 40% in price, the price of foam insulation is still the same. I paid $14.90/sheet for the plywood after my 5% Lowes card discount. My 4 windows came to about $120.
I will need to decide how to finish the walls= paint or maybe stain & spar varnish, since the plywood is so nice. I have no experience in the use of spar varnish.

[Gold5one]

I took a chance on a clearance 18x36" DH aluminum window for the rear wall. I was right, the opening is 17.5" wide and my 5000btu window A/C is 17" wide. I can make a shelf to quickly move the A/C to the window and easily remove it for travel. Theresa in their office was very helpful in answering my questions and she even sent me some pictures of some of their windows used in customer's homemade campers - I saved about $10 in shipping on my windows by buying directly.
http://stores.ebay.com/Shed-Windows-and-More/SALE-CLEARANCE-ITEMS-/_i.html?_fsub=1371488010&_sid=128008910&_trksid=p4634.c0.m322
I'm working outside and it's been sunny and dry- 78 today.

[Gold5one]

I decided to reinforce all the corners with plumber's strap today. I want bolt some electrical superstrut on the bottom of the outside frame rails for a 18" x 48" rear bumper rack, so I can bolt down a lightweight storage box or two.

[Gold5one]

Day 38-
Today I finished all the front framing and my last window (awning style) was delivered by UPS. I need to rough in some 12v and 115vac wires before I put the roof and walls on. I also bolted on my A-frame swivel jack-
The bottom of the 2x2 rafter's is 61.5" above the floor. Tomorrow I will finish the last rafter and rough in a square hole for an RV vent w/fan-

[Gold5one]

Day 39
I framed in the vent fan ( rear corner), instead of on the roof and I framed in my 10x23 fixed window. I think that one fixed and two windows that open, plus the vent fan will be enough light & ventilation. I will probably work on wiring tomorrow, as rain is due to come through late afternoon and the next day. I have a tarp to cover my work from the rain. Looking forward a few days I am trying to decide where to start with the siding- sides, front or rear? I need to start thinking about what kind of door I want= more research. I still have some small wood pieces to screw in, mostly backers for the interior siding and ceiling.
What do you think so far?

[chrisz]

Looks good!

[Gold5one]

Day 41
Thanks chrisz, I hope this all works out- I am changing stuff almost on a daily basis- I set up my chair and figured out the height of my counter across the front end, with the refrigerator in the center. I wanted the ability to set up two Ham radio operating stations for Field Day in June, but I thought about that blank wall and didn't think I would like it after a few hours of operating my Ham radio- having a window would open everything up visually. So I took the extra window and framed it in at the correct height. I then realized that I will be able to see all the way through the camper from the rear view mirror- great! That might prevent me from backing into a bull moose someday--hehe
I worked 5 hours today- with two hours out of the day to meet friends from synagogue for our annual Dec-25 lunch at the Chinese buffet.
My windows are all Made in the USA, which was hard to do and stay within my retiree budget. I'm putting a piece of Lexan over this front window to prevent a rock from breaking it.
If anyone wants some free coconuts, you are welcome to climb that 60ft palm tree in the background.
Coconut trees do not grow if there are freezing temperatures and Cape Coral seems to be the beginning of coconut palms in SW Florida. It was 75 today.

[Gold5one]

Day 45-
I got about 4 hours in today-- three days of family commitments had priority this weekend. I worked out how I am doing my roof and got started- foam board is down and sloped for the luan plywood covering, that goes on after the sides are done. I am keeping the roof light, so the camper won't be top heavy.
I am almost ready to purchase the materials to finish the plywood sides, just as soon as I decide on the color scheme for the stain- decisions, decisions. My wife noticed the refrigerator, and the roof today-Well, she says it looks I'm building a "conestoga wagon"- (spell ck doesn't know what that word is), and she would be right, if I had a good team of mules to pull it.

[Gold5one]

Day 46,
Purchased my stain, conditioner and spar varnish this morning at Lowes. I have two colors of stain, pecan and dark walnut.
I cut & fitted two of the front panels- Did a trial fit of one sheet of plywood on the side. Once I install the front plywood pieces I can begin on the sides. It was 83 degrees today- the next 5 days are forecast to be above 80 degrees, sunny and no rain. I think I can get the plywood put on, stained and brush on a coat of Spar varnish before it rains.

[Gold5one]

Day 49,
The front plywood in on- finally! Due to the extra work, it took me longer than I planned, plus New Years day was a day off my project. Tomorrow should be an easier day for me. I may get both sides done.
Rather than a tongue box, which has poor access on this design, I opted to build an faired extension. I can move the fridge forward a few inches so it is totally under the counter and the extra space behind it will be used for a wiring termination box, coax cables and a power cord. I hope this extra work translates into better mpg- it's only a guess that it does. There is another difference in the design that also is planned to help the aerodynamics on the front of the trailer. My neighbor asked me what I'm building-"It's a MMC" I told him.

[Gold5one]

Day 50,
84 degrees-
I finished the driver's side plywood today. We have 4 more days of 80 degree weather, then a cold front drops our daytime high temperature to 60 degrees. Due to weather constraints, I may have to adjust the final finish- I already had a backup plan in mind. It's called Valspar porch and deck enamel. I used that on my shantyboat and I am very satisfied with how it turned out- tough paint. I found my roof covering a Lowes today- 50% off sale.

[Gold5one]

Day 51,
Lunch break- 82 degrees in the shade
One of the reasons it's slow going, is I am sealing all edges and rear knots.


I used a temporary ledger board help install the side wall plywood- makes it an easy job for one guy.

Thanks to Mr Sun, I finally have a picture showing the narrower front of my build- almost 3" narrower than the rear. Has anyone else done this? Does it lower drag? Will my MPG be higher? I am hoping for 20mpg.

Back to work-

[Gold5one]

Whew! Am I happy the outside plywood is almost done! I'm ripping the pieces for the bottom in the back and above the door, then I' done for today. I used 7 sheets of 3/8" plywood (minus window cutouts and scrap) for the outside and two sheets of 1/2" for the floor, 2 sheets of 5mm luan for the roof plus my studding and rafters.
How much does that weight?

[KCStudly]

How much does that weight?

More. It weighs more than less would.

You are building bigger than a typical TD, too, so I guess a little heavier is to be expected, but I think you could have gone much lighter in many places and still been more than good. Since you asked.

What type of construction adhesive are you using?

[Gold5one]

I'm using pro advantage- a Lowes liquid nails knockoff
I weighted the plywood before I started= 33lbs a sheet (it's pine). Looks like I gained about 70lbs by using it. However, I saved 33% in weight by making my own studs instead of buying 2x2's ( and money too). Just couldn't find decent 1/4" BCX- it was all crap compared to what I used on my Shantyboat 3 yrs ago. I got A grade veneer for C prices, so I couldn't pass that up. Luan was out for the exterior, it won't last 10 years, which is how long I plan to use my MMC.