Death of the weekender, New Modified Benroy build

[Carl01234]

We got 6 years of use out of the Weekender, but a few years of sitting out and neglect, it is time for a rebuild. Demo started on April 28, 2018



After a few hours of demo All that was left was a trailer, the door and window.

[Carl01234]

I am going with a 10x5 Benroy on a 4x8 HF trailer. Going to add a 2nd door, and keep existing window. Air conditioner will be reused as well. Will end up with 1 1/4" framed insulated walls and ceiling, and 2 .75 inch insulated floor ( to clear wheels. ) It is gong to have a maple interior, with a cedar stripped exterior. Time for the fun to begin!

[Carl01234]

April 29, 2018

Starting framing floor. I am building a littler thicker in order to raise the floor enough to clear the wheels. I am thinking about going with a wider axle and 14 inch wheels, but wanted to have the option to keep existing. We have put over 10k miles on it as is, and I still have the 2 spare packed hub that i purchased in 2010 with the trailer that have never been used.

[Carl01234]

May 5,2018

Floor framed sheeted, insulated and glassed. Went with 1 layer of 6oz and 2 coats of poly resin. Put 1/8 inch spacer in. Glassed 2x4 's for bolt connections. Painted bottom with black hammered.

[Carl01234]

May 16,2018

After a week break to ponder, I took a long 4 day weekend and got quite a bit done. Began wall construction. The walls are 1x2, inner skin of 1/4 maple and 3/4 foam insulation. Finished walls in a day. I forgot to get pic of the curved wood wall frames and galley hatch spars. They were all cut from 3/4 maple ply and then belt sanded for conformity. I also added a 2x2 square tube and extended the trailer 18" as see on here. Much stronger A frame now. I also purchased a 2" couple that matches my boat trailer. Very quick install, just drilled out the hole.

[Carl01234]

May 18, 2018

Walls went up and began galley framing. Didnt really have a plan going in, so it was a slow process. I love how the maple looks on the inside.

[Carl01234]

Galley work continues. Fitting for the a/c. On the weekender, I vented the a/c through the floor and it worked well. So, I am doing the same on this one. Did raise the a/c to clear mattress and covers and did lose some space, but it was a good trade off.
Put some test strips up temporarily to see how it will look from outside and the ceiling inside.

[Carl01234]

All caught up now. Now to the parts Im still not so sure about. I have read through the Benroy pdf and still cant wrap my mind around how the galley hatch seals and trim are going to work. Does anyone have some close up pics of how they did the seal and then how the trim goes on over the hatch/ galley side wall? I want to use the trim from https://www.teardroptrailerparts.com/hinges---aluminum-trim.html with black insert. Which trim do I need for roof and galley hatch and which trim for bottom of trailer? I am also purchasing another door. Is there a way for me to get them keyed the same?

[Carl01234]

05/22/18

Started installing the ceiling. I was not sure how the cedar was going to bend around the radius, but it went on very easy. Going to take a lot of time installing these on both sides, the ceiling an the roof. I m trying to get a good enough corner, where no additional trim will be needed on the inside.

[Carl01234]

May 28, 2018

Worked all weekend on the galley and electrical. Didnt seem like i got much done. Galley work is slow. Going with a/c mains and a 33 amp 12v transformer for the lighting. Picked up the lighting as well.

[Carl01234]

May 31, 2018

My last build a weekender, didnt have much of a galley. This is definately the slowest part for me. I have the galley side cabinet opening cut, top shelf is finished, and an now ready to cut cab side cabinets out. Then on to final electrical. The other door, hinge and trim are being delivered today. Vintage Technologies were great to work with. Placed order on Tuesday and tracking says it is out for delivery. Very fast, knowledgeable people.

[Carl01234]

June 3,2018

Took it easy on the build this weekend, and did a little camping on the river.Did manage to get almost all electrical done. Door and hinges came in Friday.

[Carl01234]

June 4 ,2018

Got the window fitted. I remember having trouble getting it sealed last time, and it looks like the seal doesnt quite fit right on this window. I had to use lots of caulk on it last time. I took my time and made sure the opening was as small as possible this time, hopefully it seals better. Did a mock up of the cabinet doors. Take it easy on me, I an no carpenter.

[Mr. Lahey]

Nice work. Looks real good.

I like the style of your old Weekender.
This Benroy should be a nice change for you to enjoy for years to come.

[Carl01234]

Thanks!

The small wheels were really bothering me. I ordered a replacement axle and 15" wheels should be in early next week. I will now have to find some fenders and figure a way to attach them. My only concern is if Ive got enough room between fender and doors now.