10x6 Boxy, but good.

[Trevor57]

I picked up a pop up camper for $250, with plans to use it as a donor for a tiny camper. Where I live trailers need a title, and it can be tough to find a trailer with a title for a good deal. I converted a 4x8 enclosed a while back, and thought it would be nicer to have some extra width. Here is the PARTY WAGON!!!
IMG_20170616_150123071_HDR by trevor k, on Flickr

IMG_20170616_204636 by trevor k, on Flickr

Upon first inspection, it wasn't terrible. The previous owner had gutted most of the camper, and put stick on floors, there weren't any huge holes in the canvas, and the lift mechanism worked fine. It did smell like mold, and the door didn't work right. The more we looked things over the worse it got, and my brief thought of camping in it as is went away as quickly as it came. So we started tearing into it.

IMG_20170617_151629701 by trevor k, on Flickr

IMG_20170617_151639227 by trevor k, on Flickr


With my 9, and 10 year old kids, we made quick work of the tear down. We had it apart, sorted, and cleaned up in 2 days. Would have been quicker, but I wanted to separate the metal. I scrapped the aluminum, and got $26.

IMG_20170618_182106017 by trevor k, on Flickr

This is the real reason I bought this pop up. A wide trailer, in good shape.

IMG_20170618_182122139_HDR by trevor k, on Flickr


I spent today wiring, doing the floor, running to HD, and moving right along.


IMG_20170621_113608577_HDR by trevor k, on Flickr

IMG_20170621_120536461_HDR by trevor k, on Flickr


Not a terrible first day. Though I did think I would get the floor done, so I could flip it over, to paint the underside.

[Trevor57]

......

[Trevor57]

Reserved for future update

[Trevor57]

Reserved for future update

[Trevor57]

Reserved for future update

[swoody126]

LET THE FUN BEGIN

gotz me a big ole glass of SWEET TEA an'a



LOTSA PICS PLEASE

sw

[Dutchoven61]

Wow, I have the exact trailer. all of your photos look like mine. I am completing the walls and roof the spring. My camper is a standee tall enough to stand up in. Im calling mine the TARDIS because its bigger on the inside than the outside. Also I plan to use FRP for the skin and roof. Cant find Aluminum cheaply here in S.E. Wisconsin.

Keep going, you will like what you get. Ill try to post some photos soon.

[Trevor57]

Yesterday, I finished the floor, and then did an undercoat on the base layer of the trailer

IMG_20170621_202803970_HDR by trevor k, on Flickr

IMG_20170622_203845235 by trevor k, on Flickr

IMG_20170622_221922296 by trevor k, on Flickr


Also got started on the walls. I already regret not doing a skeletonized sheet of 3/4 ply for the inner sandwich layer.

IMG_20170623_141544748 by trevor k, on Flickr

[Trevor57]

The next group of pictures were taken over the month of July, although I was on vacation for part of the time.

Here is a shot of the first wall up, notice in the background, the finest automobile ever made. The Volvo 245.

IMG_20170626_123002821_HDR by trevor k, on Flickr

...and wall number 2. luan, 3/4 pine, and 3/4 insulation

IMG_20170626_125239046_HDR by trevor k, on Flickr

The angles, outline, and "feel" of this camper is inspired by one of the cars that will tow it. The Volvo 240 wagon. That is the reason the front has the sharp angle instead of a teardrop shape. It did make things a little interesting because there are seams, instead of bends.

IMG_20170626_171236713 by trevor k, on Flickr

I built parts of the front cabinet as I went, since it is part of the front structure, and helps with strength. I was a little concerned with racking at this stage, but it turns out that wasn't really an issue.

IMG_20170629_130408395_HDR by trevor k, on Flickr

Another shot with the first roof span.

IMG_20170629_130416995 by trevor k, on Flickr

Checking to see how it will look.

IMG_20170630_155330491 by trevor k, on Flickr

Walls, roof, and "windshield" completed, and insulated.

IMG_20170702_172339150 by trevor k, on Flickr

[Trevor57]

At this point I began to work on the hatch. Here are the first couple pieces.

IMG_20170702_172350523 by trevor k, on Flickr

Mostly together. There were some wierd gaps at the one joint, but I filled them with bondoglass. Hiding your crimes is sometimes easier than following the rules.

IMG_20170703_221238293 by trevor k, on Flickr

Skinning the camper in luan. Now I can say that I would not have done it this way, knowing what I know now. Not only was it probably more expensive, it was way more work. I am sure I will build another one, and have plenty of things that I will do differently.

IMG_20170705_140338490 by trevor k, on Flickr

Got the thing skinned, and first coat of epoxy resin. All of the seams are reinforced with fiberglass mat.

IMG_20170719_113050 by trevor k, on Flickr

I painted the camper blue, as you can see. Here is the galley area starting to come together.

IMG_20170802_130128053 by trevor k, on Flickr

A face frame, and the hole for the ac wall unit.

IMG_20170802_130140572 by trevor k, on Flickr

The hinge, and hatch installed.

IMG_20170802_192520861 by trevor k, on Flickr

Profile shot.

IMG_20170802_194434498 by trevor k, on Flickr

A few pics of the aluminum trim being bent, and shaped around corners and edges.

IMG_20170803_195809838 by trevor k, on Flickr

This camper has made a great place to let face frames dry after stain.

IMG_20170803_195821694 by trevor k, on Flickr

The start of the aluminum edging for the ac unit. You can also see some of the runs from the epoxy. I have only worked with fiberglass once before, and this was a learning experience. I considered sanding, and bondo. It's not worth it to me, and I could also do that down the road if it were to bother me too much.

IMG_20170803_201419463 by trevor k, on Flickr