Building our 6 x 10 benroy

[AllenS]

It was suggested that I start a build journal, so here goes.

What I’m building is a 6 x 10 benroy. It’s actually 5.5 x 10 because we couldn’t locate a 6 x 10 trailer to put it on, and I don’t have the equipment to build one, but we'll be able to fit a queen size mattress in there so that’ll do.

So far I’ve got the floor insulated, sealed up and bolted to the trailer. I’m now working on the side walls. I already have aluminum sheeting, the doors, port holes, ceiling vent and other odds and ends piled up against one wall in my garage. I made the last big purchase last night, ordering the lights, battery, 100w solar panel and various other things needed for the electrical system. So long as I don’t completely screw something up, the only things I have left to purchase for it are plywood and spars for the ceiling and roof.

Of course, the wife still hasn’t made up her mind about the interior décor...

There isn't much to show yet but I'll upload more photos as I go.

[bam1028]

Hey that's a great start. I like the benroy shape you have created. Thanks for sharing

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[AllenS]

One thing I'm learning throughout this process, is that I can't follow a line with a router to save my life.

[KCStudly]

Clamps and a straight edge are your friend.

[AllenS]

Clamps and a straight edge are your friend.

Yeah. Finally figured that one out last night.

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[AllenS]

An update here is long overdue.

I did a bunch of work on the teardrop toward the end of the summer, and through the fall, but haven't touched it in a few months now. I'm planning on getting back at it soon so that we can use it this spring.
I'm a little further than what's in these photos. I have quite a bit of the electronics wired into it now, but haven't yet touched the galley or the hatch.

We're both very pleased with how it's coming along, and it's been a fun project.

Click here to see the photos

[Staryder61]

Looking really good Allen. Moving right along..
How are you planning on venting the AC?

[AllenS]

Looking really good Allen. Moving right along..
How are you planning on venting the AC?

Thanks!

I'm putting a vent in the roof, right above it, and possibly a bit of duct work in one side for the intake, so that it's not sucking in it's own exhaust.

[AllenS]

Got the TV mounted over the weekend, started on the port holes in the ceiling, and also got started on the tongue box that's going to hold the battery and the power center.

I was against having a TV in the teardrop, but my wife was very insistent. So there's a TV in the tear drop. It's a nice, little 12 volt, 19 inch LED screen that got good reviews on Amazon. I'm setting up a Raspberry Pi as a media center, so we can watch movies off of a USB hard disc, or stream things if there is a wireless connection handy.





The port holes turned out to be trickier than I anticipated. We're putting them in the ceiling, to allow more light in. The ceiling/roof is going to be almost two inches thick, and the port holes aren't designed to be used in a surface that thick. Namely, it renders the trim pieces that came with them useless. So I fired up Google Sketchup and modeled up some of my own, and I'm printing those off on one of the 3D printers at the library where I work. I printed off a test section yesterday, and it looks pretty good. It's nice and smooth, I'll be able to drill holes in them to mount them, and I'm printing them in white so that we can paint them.

I originally planned to put the battery and power center in the galley, but with everything we want to put back there, there just isn't enough space. So I'm building a tongue box, and I'll be putting it all in there. I'm planning on using some old PC fans and dryer duct to provide some airflow through the thing, and hopefully keep the temperature down in there. I don't know that I'll have enough left over aluminum to skin the tongue box, so for now I'll just put a good water seal on it, and paint it. I'll dress it up when the budget is more cooperative.

There isn't much left to do. We're not planning on finishing the galley right away. I'm going to put some simple shelving and cupboards in there to start, and we'll camp it a few times to get an idea of how we want to arrange things back there. I'll either finish that up later in the summer, or this fall/winter.

At this rate, if I keep on it, she should be ready to camp by the beginning of May.

We're both very excited about it.

[steve cowan]

Great job you're doing.Looks very nice.

[AllenS]

Great job you're doing.Looks very nice.

Glad you like!

[AllenS]

Making pretty good progress. I've been working on it every Sunday, and when ever I can manage on week day evenings. I think we're on track for our May 1st deadline.

The cabin is basically finished, just needs a bit of touch-up work. I'm putting together the galley now. After that it's insulating and sealing up the roof, then the hatch, then time to skin it!