Generic Benroy - what about the roof?

[UT Slim]

I finally got a 5 x 8 trailer from RedTrailers.com and am looking forward to getting started on my build. I'll be sticking pretty closely to the Generic Benroy plans. However I don't see any discussion in the plans for skinning / attaching the exterior roof. I've done some searching around past messages and am more confused than ever on what to use. I have some 1/4" ply on hand but it doesn't seem like it will be able to bend around the tighter radius of the front of the trailer without breaking. Then there are suggestions to use one layer of 1/8" ply and others to use two layers of 1/8" ply. A single layer of 1/8" ply seems a little thin but if others have had success with it...I might try it. I'll be applying CPES then painting the roof.

Another issue is the material. Most recommend Baltic Birch plywood. Why Baltic Birch? Or what about just 'Birch'? At my local big box suppliers the only 1/8" ply I can find is 'Honey Maple' - not even 1/8 Luan. The contractor oriented lumber yards I've checked around here (so far) only have 1/4" birch, no 1/8", and no grade specified. I guess I might have to order this. So, can someone set me straight here? I really want to get started but I have a feeling if I grab the first available material to do so I might have trouble later on.

[mikeschn]

Hi UT...

Are you reading the FREE plans that are up there in the menu?

On page 38 it tells about the headliner.

I didn't specifically talk about the outer roof skin, which should also be 1/8" birch.

I chose baltic birch so that you could build the headliner, and the roof skin with just 2 sheets of 1/8" 5' x 5'.

You could use regular birch, but you'll have to adjust the location of the seams. It could get a little tricky cause you may have a seam in the area for the roof vent.

On the outside I like two layers of 1/8" plywood, because it is like you say... thin!!!

Mike...

[Isalvus]

Slim,
I went through the same thing, but my roof line is even more drastic than the Benroy. I modeled it after another tear on this site. The problem was that some of my bends were almost 90 degrees even though they had a pretty large radius. I couldn't find anything that would make that bend (I even threw a peice of luan in my pool for a few hours to soften it.... didn't work). Plus my trailer is 63.5 inches wide and I need the bend to be in the length direction not width. I was able to find plywood called Bend-a-Board (you might find it under another name). Bend-a-board is used a lot in cabinet making and boat building. It is very light and comes in all thicknesses (I bought 3/8 ). It bends like a dream, no need for tons of clamps or lots of elbow grease. Its not that expensive about $35-40 a sheet and worth every penny. If your going to use CPES it'll will seal just as good as birch. Sorry about the long rant, good luck!

[Isalvus]

that should say I bought 3/8"

[Miriam C.]

that should say I bought 3/8"

When you use 8 and ) you need to space them out or you get the

How fun is that!

[bledsoe3]

I've got one layer of 1/8" Luan the top of my tear. I've got about 7 gatherings and close to 5000 miles and no problems so far. Of course I wouldn't stand on it either.

[jmtk]

Hi Slim,

How'd I miss you? First off, welcome to the forum from another Utahn! Secondly, MacBeath's Hardwoods at 1576 S. 300 W. is baltic birch heaven! I swear I bought some of every thickness from 1/8" to 3/4". The prices aren't bad either.

I used 1/8" for the ceiling and 1/8" for the roof with 1.5" framing and pink insulation between the two layers. I coated the outside with CPES before varnishing. It's hanging in there just fine so far.

Jeanette

[Mary K]

Pictures folks, Pictures!

I skinned the exterior with 1 layer of luan glued to the spars and stapled.


Then, I skinned with another layer of 1/8" 4x8 birch cut to 5 ft wide. I glued it to the luan and used ratcheting straps
to hold it down while it dried.



I hope This helps.

Mk

[mikeschn]

Thanks for helping out with those pics Mary K.

Mike...

[UT Slim]

Great responses, and much appreciated! The pictures are a big help too.

Jeanette, thanks a bunch for the tip on MacBeath's - I'll definitely check them out!

Mike, I'm not sure if I quite understand about Baltic vs. plain birch, is there some stock sizing issue here? Keep in mind you're talking to pretty much of a rookie woodworker so I'm in unfamiliar territory with respect to the materials.

Again, thanks to everybody for answering. Looking forward to finally getting started!

[jmtk]

Slim,

Baltic birch comes in 5'x5' sheets, so is great if you're making a 5' wide trailer. I have very limited woodworking skills, too, but it was obvious to me that the baltic birch was better quality than the 4x8 sheets of birch, both of which I got at MacBeath's. If I had to do it all over again, I'd have used the baltic birch for everything. The outer sidewalls of my trailer used the 4x8 sheets, everything else (inner sidewalls, roof, ceiling, floor) is baltic birch.

Jeanette