background
i spent most of my life in the southeast US, but moved to canada a year and a half ago. i live in a small town on the prairie in manitoba where the winters frequently get down to -30C (really freakin cold F). and while the summers aren't quite as hot as i'm used to, they're still hot. i have always loved hiking and spending time outdoors, and i like the abstract idea of camping but have never been able to sleep in a tent.
hobbies include woodworking, building electric guitars/basses (and playing them occasionally). i've done some fiberglass work before (paddleboard and restoring a small sailboat), and i have experience with carpentry, electrical, plumbing, etc from building a tiny house and a few other things. i have all the tools i can imagine needing for this project, and i have a lot of time to work on it for the next couple weeks.
i've designed this build to suit my situation, which includes 4-season camping with my partner and large dog, and towing with a 2019 outback. i'd like to use it for winter camping/snowshoeing/etc so that is a major reason for some of the design choices. i'd also like to start using it as soon as possible and make decisions about where/how i want things after i've used it a few times. i've chosen not to go with a rear galley kitchen mostly for reasons related to winter camping. so what i'm starting with is a pretty simple shell that i will customize later (while trying to plan ahead to make that process as simple as possible).
the trailer
i've spent several weeks trying to source a used trailer that would work, but haven't been able to find anything locally. in the future i might build my own, but i wanted to be using this one instead of learning to weld. i looked at a couple trailer dealers and all the big box stores here (home depot, rona, canadian tire, princess auto). i didn't want the added height of building up and out over the tires of a narrower trailer. i found a pretty inexpensive 5x8 galvalume kit. i wasn't opposed to the assembly, but i wanted to end up with a 5x10 camper and was concerned about overhanging too far on the back or taking up space on the tongue that i want to use for other things. the only other option that looked good was this 5x10 from home depot that i purchased yesterday. i'd seen one used on facebook marketplace, but someone beat me to it, so i bought one new. i like the galvalume finish for durability and appearance. if i were keeping it as a utility trailer, the folding front gate and ramp would be nice features, but alas...i have other intentions.
day 1
i spent the morning removing the front and rear gates, side walls, and deck, and grinding away the corner posts that are structural (and removing the gravel and dust that had accumulated driving home down back roads). i'm happy with the bones, and the only complication i've noticed is that the frame is actually about 64" wide--it was 60" from one side wall to the other. as much as i'd like the additional width, i'm locked in to 5' because i'm using 5x5 baltic birch sheets. i'm sure i'll come up with something, but would happily entertain suggestions.
after i stripped it down, i built the subfloor/floor assembly. i framed it with 2x4s that i ripped down to 2 1/8" to match the thickness of my insulation. rigid foam options are different from what i'm used to because it's used differently because of the winters. the purple stuff is really expensive, and the GPS foam sheets have the best r-value/cost ratio and i have been happy with them under the floor of my shed. my only concern is the bond from the construction adhesive not being as effective because the foil coating can peel off, but even if that failed, it would be fine and it seems really unlikely that i'd ever find out. anyway, i'm using the same 2 1/8" r-10 GPS foam for the floor, ceiling, and front/back walls. the bottom is 3/8" exterior plywood, attached with construction adhesive and deck screws, and the floor is 1/4" baltic birch, attached with construction and finishing nails that i hammered in because my air compressor decided to take a break. i'll trim off the excess with a router/flush trim bit tomorrow. i had considered using 1/2" baltic birch for the floor, but decided to save the weight, and i'm happy with the decision. it's plenty firm.
next up, the walls.
