theoldwizard1 wrote:rowerwet wrote:I built a couple foam kayaks before building my teardrop so that I would be used to thinking and working with foam, before I built my big foamie.
I am very surprised you used plywood for the floor on your foamie build seeing as that is what killed the old pop-up.
I am thinking long and hard about using something else for the floor besides plywood. It you use C-channel or light weight I-beams and divide the whole chassis into no bigger than 2'x2' sections ad used something like Fosmular 600/1000
(so each 2'x2' foam square is supported on all 4 sides by a 2" piece of metal) I am hoping it is strong enough to hold 400-500 lbs.
If I have to use plywood, it will be MULTIPLE coats of The Mix, top bottom and sides.
The difference being the fabric skin.
Once the tear box was complete, I lifted it off the trailer frame, and set blocks under it so I could work under it easily.
It only needs a 4x4 between the frame and floor to do this.
Then I wrapped the sidewalls with canvas, wrapping the top over the roof almost a foot, and under the floor almost a foot.
All fully glued with TBII.
Before I started building, I also coatedon't the floor with deck sealer, except for the edges where the fabric would be stuck.
Theroof fabric went over the top and was left with the edges sticking out a little.
After I filled all of the canvas with paint, I used a razor blade to trim the edges of the roof fabric off flush with the sides.
After the paint cured I dropped the box back onto the frame and bolted it down.
I used a trolley jack and a rubber chock to lift and lower the body.
The floor plywood will only get damp if I tow it in the rain