Doghouse Build v1

[johnb]

This site has been so much help for me that I feel an obligation to contribute and hopefully help others who are thinking about building.

After looking at kits and reading through this forum I've decided to launch into building a teardrop from scratch - partly because I feel I should be able to do this, partly because it is a good project for the family and partly for the self-satisfaction of making something myself.

My wife has named this the doghouse - due to the size primarily, perhaps it is where I'll need to go when we disagree...

Here is the starting point for me
- no experience in working with metal
- significant comfort in working with wood and laminate
- limited hand tools - drill, circular saw, router, jig saw and various non-power hand tools
- budget of 5 k for material, hardware and new tools - I don't like cheap tools but am happy with inexpensive ones. I'm happy to post a cost summary if there is interest and am keeping a running total.
- need enough space to fit myself, wife and 6 year old
- I have a full time job so this is an evening and weekend project

We settled on a stretched version of the 'New Cub' design listed in this site. Floor to be 5x9 feet, will try to arrange a bunk of some kind - to be sorted out when the spaces are closer to finished.

This started exactly two weeks ago when I purchased 2x2 steel in Burbank and bought an arc welder, small grinder and metal saw. The first 1000 bucks went fast.

Welding is great fun to learn - spent a 1/2 day practicing on scrap and then dove into the frame. The good thing about welding is that it is easy to tell when you have done a crappy weld - the bad thing is that I'm not aware of a good way to test if the weld that you think is good to prove that it is good (at least with affordable home equipment). I ended up grinding down and re-welding anything I had any doubts about. Here are some pics of the frame:





I tried to do a simple floor - this is 1/2 inch 5 ply with a flat 2x4 outside pine frame and 1x2 poplar strips. With all the support of the trailer frame this seems to provide a very sturdy base - heavier than I would like though.



So far no big mistakes...

[starleen2]

My wife has named this the doghouse - due to the size primarily, perhaps it is where I'll need to go when we disagree...

Remember that the dog house can work both ways! Seriously - looks like fine start

[Miriam C.]

Your welds look great from here. 2x4 might be heavy since you have 1/2" floor too. Depends on what you want your weight to end up.

[jamesm]

Looks good I have about $500 in my tear now. I mostly was given or asked for the building supplies, trailer, etc. So your budget of 5k shold be no problem. Keep up the good work and keep us posted.

[johnb]

Thanks for the feedback. Yes this can be done for much less money, definetly would be cheaper to get a harbor freight trailer. Also cheaper if you have tools - drill bits, router bits and other miscellaneous items are adding up.

I can see patience is key for this - everything takes time to find, order, learn how to use and apply. Taken the frame as far as I can without an axle (on order). The idea is to make it possible to detach the frame from the living quarters so I welded on a series of tabs to the frame to bolt through the 2x4 flat frame. I'm thinking the sides will attach to the wood frame and not overlap onto the frame.




Meanwhile the sides are getting some attention - need to do some research and figure out how to tackle the hatch soon.

[peggyearlchris]

Looking great. Now the fun begins. Peg

[johnb]

Well it's been awhile since an update. Recently got the axle welded on and mucked around with the fenders for far too long. I fabricated the fender back splash from thin gauge steel sheet and welded some angle iron together to get it the right distance for the wheel. End result is mobility - trip around the block didn't show major problems

I used the rot doctor CPES on the bottom and sides of the deck and covered the bottom with home depot roof tar. Probably overkill ... I left the sides of the bottom with only the CPES as I'm planning to fiberglass all the joint edges. I figure it can double as a boat...

Flipped the deck right side up and put spar urethane on the floor.


Also decided to finish the sides before putting up - the spline will be the end of the interior compartment.


Seems like I've done more but I guess not -

I've grown on the idea of putting a cot across the inside for the little man - will have to figure this out later. Ordered fan and more CPES - the stuff stinks for far too long but really seems to soak in a and seal up nicely. More overkill.

Total cost is over 3,300 - 1300 on tools, big ticket items so far are doors from little guy, axle, roof vent. Could defintely do it for less.

Rear hatch is next big hurdle...