Small caravan box by Tom

[dales133]

Nice progress keep up the good work

[ipy]

Once I finished lower part of the caravan, I started working on its roof. Decided to cover it with PVC panels, because they are lightweight, yet strong and water-proof. Panels are quite wide but still there were connections between them on a flat surface of the roof. In order to give this connections more water resistance, I filled whole lengths with a glue-sealant.

Applied a bit too much of this glue and that caused very narrow gaps between flat surfaces of panels. They were still water-tight but it did not look good to my eyes and I supposed it would be even worse when dirt would collect there.

So after I sealed all connections between PCV panels on a whole roof and a front of the caravan, I added a layer of polycarbonate panels, with chambers running perpendicularly comparing to PVC panels. First I applied every second piece of polycarbonate, then the rest. Finally I sealed panels with another layer of a sealant.

Now the surface is nice and flat but because of the fact that polucarbonate is transparent, I need to cover the whole thing with the last layer- self-adhesive foil, white in colour.

[ipy]

Next part of my work was to apply last polycarbonate panels and to seal whole roof and a front wall with a transparent sealant.

Then I designed a solution for fitting side handles. I used a plastic sticker (with some text written on it)- applied it on a previously painted part of MFP. Then came a PVC profile and an original handle made by Niewiadow. Next to the handle there is a small hole drilled in PVC profile. Purpose of this hole is to be a base for fitting a half of a hinge- another half there will be on a construction on which my caravan will be stored when I use a trailer for other purposes.

There are four sets of handles and hinge havles- one in each corner of a caravan.

I also prepared 4 holes in a front wall, bigger in polycarbonate and smaller in PVC. They perfectly fit ventilation caps. Installed only one cap at the moment, just to check if it is okay.

Then I applied PVC panels on a right side of my caravan. You can see a hole which will be covered by a hatch to be open down. When down, hatch itself will become a kitchen table and will open a kitchen area.

You can also see a polycarbonate panel applied at the lower part of caravan`s rear wall- this will be inside trailer boards. So when we want to access the caravan, we need to open trailer`s rear board (hatch?).

[KCStudly]

Looking very nice!

[ipy]

Next wall to finish with PVC panels was a left one. I needed to cut a proper shape of a hole for a window. When I finished working with both side walls, I cut and fitted rounded corners in window holes made in MFP (there were rectangular holes previously).

Unfortunately, my camera lens does not cover the whole left wall as it is too close to a garage wall, so I show it in 2 pictures.

Last step was to frame both side walls with PVC profiles so that they end in a straight line. The same thing I need to do with edges of a roof.

[ipy]

Today I applied two strips of a white self-adhesive PVC to the roof of my caravan. They cover the whole length, from the very front to a far end of the roof. There will be another white strip in the middle, but I neet to wait a while until those applied today dry out.

I will cut holes for window and vents when all stripes are applied.

All edges are finished with PVC profiles and they are ready to apply last profile that will connect existing ones.

I am also painting edges of doors and a kitchen unit.

Now I have very little time to work so my pace slowed down. Still, I hope to enjoy first trips with a caravan in mid June.

[ipy]

My wife and me managed to apply silver self-adhesive PVC foil on both sides of a caravan. The purpose of this foil is to protect PVC panels underneath form UV.

Foil will be finished (cut on edges) after it dries. Still need to apply a white strip in the middle of the roof.

[Sheddie]

Well done Tom
I assume that the foil is the same stuff that is used for vinyl wrapping vehicles for sign writing?

[ipy]

Yes, the adhesive PVC foil is the same as vinyl wrap.

Today I applied the last white strip as well as grey pieces around windows. It looks really nice and tidy and it was so easy to do.

I am approaching the big day, when my caravan box is filled within trailer boards. Hope it will be next week.

[Sheddie]

Looking good Tom.
What do you plan to do with the rear panel?

[ipy]

Today I applied silver self-adhesive strips to the whole length of the roof so to cover edges of separate vinyl wraps and protect them from water going in between. I also installed all vens in the front.

Started to build a kitchen door. It will open vertically towards front of the caravan. When open, it will allow to open down kitchen table and give access to a sink, gas burner etc.

Kitchen door will be made from MFP with holes to make it lighter, wooden frame and PVC panels covered with silver vinyl wrap as a finishing surface.

I applied self- adhesive PVC foil with steel texture to the lower part of a rear panel. Upper part will be finished with a purple PVC foil, to fulfill my wife`s and daughters` wish. Upper part will be covered with a hatch (I suppose finished with silver PVC foil) becoming a roof when open.

[ipy]

I designed a logo that will be placed on a rear hatch of my caravan. It says ZipZapZop Trailers and generally means nothing but I like the way it looks. Let me know what do you think about this idea.

[noseoil]

Tom, you're making good progress on the build. I like the logo you've created & think it will look good on the finished walls.

Do you have a weight estimate yet on the completed project? I'm just wondering how much it will weigh, since you can put it on and take it off when you want.

[ipy]

Here in Poland we use metric units. We measure weight in kilograms. For example my compact car weights about 1400 kg. Small city car weights about 1100 kg. Empty utility trailer weights 135 kg. Maximum weight of a trailer without brakes allowed to be towed by my car is 500 kg.

At the moment my caravan box weights about 120 kg, a bit less than an empty utility trailer. I calculate that when finished, it will be as heavy as 200 kg.

Average adult man is about 80 kg.

So the capsule (without equipment) will be as heavy as 2,5 men. Could be lifted by 4 men holding 4 handles in corners of a capsule.

I did not want the capsule to be too light beacuse trailer would jump on road. Maximum weight of my trailer with full payload is 750 kg, so I think half of this value would be perfect for driving stability.

[ipy]

Today I applied last coat of paint on window and door surroundings. Cut out a door frame from MFP. Also double-side taped styrofoam on a trailer floor. This is a kind of an insulation stuff that can be put under flooring panels. I think it is strong enough for a capsule installed on it.

The big day of fitting capsule within trailer boards is approaching. Today I want to build a construction to help me lift the capsule up.