Project Tear Hauler (UPDATED 3.7.11 MAJOR PHOTO ADDITION )

[fbaly]

Project Mission Scope:

To build a tear drop trailer that will serve two purposes.
1. Camping!
2. Haul motorcycle!

The design:

Used a classic look and changed the dimensions. Removed the galley kitchen and increased the height and width.

We started with a 1/4 scale model to see if it would look good!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs630.snc4/59001_715583108661_11011175_40755268_5387350_n.jpg">

Then a full scale cut out
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs315.ash2/59520_715583203471_11011175_40755276_7398943_n.jpg" >

Purchased a trailer.
The trailer is a 5x8 trailer from Northern Tool.
It came in these boxes:
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs309.ash2/58919_715583033811_11011175_40755261_4514132_n.jpg">

The process of putting the trailer together was long.
The right wheel hub was busted up. So needed them to replace it.
Getting the tag for this trailer was also no fun. They didn't send the paper work that was needed to register.

The parts!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs204.ash2/46718_715583253371_11011175_40755280_78525_n.jpg">

The trailer together!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs299.ash2/57975_715583343191_11011175_40755285_1605143_n.jpg">

The start of the 2x4 treated wood frame.
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs323.ash2/60346_715583373131_11011175_40755287_973838_n.jpg" >

Pocket holes holding it all together.
The wood frame was also bolted down with bolts and nuts!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs208.ash2/47123_715583388101_11011175_40755288_5891571_n.jpg">


Tar the floor
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs659.snc4/59943_715583442991_11011175_40755293_2205195_n.jpg">

Tar the floor and the treated 2/4
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs336.ash2/61603_715583477921_11011175_40755296_6643922_n.jpg">

The floor sandwich is:
3/4 treated plywood bottom side with tar
then the 3/4 insulation with 2x4 treated frame with tar
Then 1/4 plywood that was also tar on the bottom....
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs214.ash2/47702_715583522831_11011175_40755300_6802443_n.jpg">


Now to finish the floor (important note: don't used the stick on fake floor on pressure treated plywood! it wont stick very well!)
Snapped a chalk line for straightness!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs416.snc4/47885_715583542791_11011175_40755301_6946906_n.jpg">

Floor almost done!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs323.ash2/60297_715583612651_11011175_40755307_42047_n.jpg">

Add some weight and wait a while...
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs210.ash2/47285_715583627621_11011175_40755308_2088304_n.jpg">


This was the first round.

[fbaly]

Alright the next round of pictures!

Time to add wallz!
We used 1/4 inch plywood (utility)
Each wall will used up 4 sheets due to the size. That is a total of 8 sheets!

Due to the kitchen not being inside anymore issues came up with the design.
How would we stop the wood from curving!
Solution add metal!

We purchased 3/4 x 3/4 inch steel.
This is how it went!
Cleaned and clear coated for protection
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs985.snc4/75875_737908648101_11011175_41377280_5067552_n.jpg">

The lay out.
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1188.snc4/150999_737908428541_11011175_41377267_6457199_n.jpg" >
6 Horizontal bars within each wall.
Total 12.
Custom made 3 inch x 3/4 inch brackets (cheaper then buying them at lowes)
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1221.snc4/155375_737908458481_11011175_41377269_4363311_n.jpg">

first one up
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs570.ash2/149224_737908468461_11011175_41377270_4436568_n.jpg" >

More
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs606.ash2/155825_737908588221_11011175_41377277_5218887_n.jpg">

Drilling hahahahah
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs593.ash2/154557_737908702991_11011175_41377283_5094958_n.jpg">

Wall 1 done!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs606.ash2/155799_737908712971_11011175_41377284_6192044_n.jpg">

Heather being organized
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs998.snc4/77112_737908752891_11011175_41377286_4490512_n.jpg">

Add wood so we could screw the sides on!
Also used 3 bolts and liquid nails..

<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1181.snc4/150339_737908787821_11011175_41377288_294757_n.jpg">

Clamps!!!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-ash2/hs488.ash2/76172_737908812771_11011175_41377289_3909265_n.jpg">

The door fitting! What a pain in the ass!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs983.snc4/75647_737908837721_11011175_41377290_8266828_n.jpg" >

Out side part of the wall
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1153.snc4/149524_737908977441_11011175_41377300_5401399_n.jpg">

<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs948.snc4/74183_737909032331_11011175_41377303_8144475_n.jpg">

Wall in with window/door
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1202.snc4/155491_737909132131_11011175_41377307_5735555_n.jpg">

Heather showing me the door works!
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1130.snc4/149278_737909167061_11011175_41377309_2285689_n.jpg">

Wall 1 done! Added a 2 inch boarder around all the outside.
This took a long time! made each one of those pieces with 1/4 plys...
<img src="http://sphotos.ak.fbcdn.net/hphotos-ak-snc4/hs1136.snc4/149859_737909177041_11011175_41377310_4453309_n.jpg">

Thoughts?

[Miriam C.]

You have a wonderful start to a great Teardrop! Keep the pictures coming.

[vtx1029]

Looking good, but I would have found a friend with a welder lol

[S. Heisley]

It looks like it will be good and sturdy, which is what you will need to haul that motorcycle! Thanks for sharing your build story and pics.

[Trentb]

interesting

[fbaly]

<img src="http://farm6.static.flickr.com/5016/5502842160_984f1d2cbd.jpg" width="500" height="374" alt="" />
Door test fit went well. As you can see a 2inch frame following the curve was installed all the way around. All those parts were made with single 5mm plys..... Next time ill just buy another 3/4 board instead of saving every piece of wood left over.

<img src="http://farm6.static.flickr.com/5298/5502843298_729100b725.jpg" width="500" height="374" alt="" />
Blue foam board added. Woooohooo

<img src="http://farm6.static.flickr.com/5173/5502844316_6f9a859be2.jpg" width="374" height="500" alt="" />
What a nightmare. The spray foam moved all the blue foam. Had to redo and it took more time.


<img src="http://farm6.static.flickr.com/5055/5502845560_2efb823b2c.jpg" width="500" height="374" alt="" />
Last part to be sealed off.

<img src="http://farm6.static.flickr.com/5140/5502846460_b43d7abdb5.jpg" width="500" height="374" alt="" />
Both walls waiting for upgrades

<img src="http://farm6.static.flickr.com/5180/5502255369_6eba3151fc.jpg" width="374" height="500" alt="" />
Metal doesn't bend as easy as wood.

<img src="http://farm6.static.flickr.com/5053/5502849998_78d9a50ef3.jpg" width="500" height="374" alt="" />

<img src="http://farm6.static.flickr.com/5220/5502849078_e67fd50491.jpg" width="500" height="374" alt="" />
Laminate bending form 1st attempt

<img src="http://farm6.static.flickr.com/5220/5502850258_e3c3c68893.jpg" width="374" height="500" alt="" />
Laminate bending.. What fun to learn

<img src="http://farm6.static.flickr.com/5098/5502850828_d1eb4370b1.jpg" width="374" height="500" alt="" />
Make sure you have plenty of clamps. The more the better !

<img src="http://farm6.static.flickr.com/5176/5502259091_7ce826ee11.jpg" width="374" height="500" alt="" />
Putting In the inner skin. (A BITCH to do)

<img src="http://farm6.static.flickr.com/5179/5502853172_ecc47b083a.jpg" width="374" height="500" alt="" />
Tongue Box! What what

<img src="http://farm6.static.flickr.com/5140/5502853454_f426aed99a.jpg" width="374" height="500" alt="" />
As you can see still no rear hatch... IT scares me.

<img src="http://farm6.static.flickr.com/5011/5502853788_bc9626acc8.jpg" width="500" height="374" alt="" />
Before paint was added

<img src="http://farm6.static.flickr.com/5176/5502854086_e15429039c.jpg" width="374" height="500" alt="" />
Primer ( I hate painting)

<img src="http://farm6.static.flickr.com/5253/5502262331_369caf0a56.jpg" width="500" height="374" alt="" />

<img src="http://farm6.static.flickr.com/5057/5502854754_dc85c1bb8c.jpg" width="500" height="374" alt="" />
Looks sort of small. But it isn't

<img src="http://farm6.static.flickr.com/5300/5502263239_c9f0a5e9ff.jpg" width="500" height="374" alt="" />
Just finish painting the inside. Not so happy with the final result but it will do. The outside will be way better.

<img src="http://farm6.static.flickr.com/5057/5502263545_d00575161f.jpg" width="500" height="374" alt="" />
Outside moving to another garage

<img src="http://farm6.static.flickr.com/5259/5502265491_b3f70bd381.jpg" width="374" height="500" alt="" />

<img src="http://farm6.static.flickr.com/5132/5502265867_95c086fa4f.jpg" width="374" height="500" alt="" />
Side view after 3 coats of CPES

<img src="http://farm6.static.flickr.com/5131/5502858400_81dd27e657.jpg" width="500" height="374" alt="" />
Hatch what a nightmare

<img src="http://farm6.static.flickr.com/5096/5502858970_d4516e1379.jpg" width="374" height="500" alt="" />
This will hold the radio. You will also see my custom switch panel.

<img src="http://farm6.static.flickr.com/5055/5502858692_4056fa03b6.jpg" width="500" height="374" alt="" />
Side view with speakers, led lights... and radio

<img src="http://farm6.static.flickr.com/5097/5502859280_7eb5b06855.jpg" width="374" height="500" alt="" />
Wires before they were cleaned up. And spray foamed

<img src="http://farm6.static.flickr.com/5218/5502859574_ae1eb3f1c0.jpg" width="500" height="374" alt="" />
Spray foam.

<img src="http://farm6.static.flickr.com/5172/5502860506_d9e2ee104f.jpg" width="500" height="374" alt="" />
Tongue Box inside

<img src="http://farm6.static.flickr.com/5132/5502268665_2887b45733.jpg" width="374" height="500" alt="" />
Tongue Box bottom, Includes power in and also includes GFI plugs

<img src="http://farm6.static.flickr.com/5171/5502861178_aee99e65d8.jpg" width="374" height="500" alt="" />
Side View

<img src="http://farm6.static.flickr.com/5095/5502269379_16ee02bac6.jpg" width="374" height="500" alt="" />
Up close and personal with the side

<img src="http://farm6.static.flickr.com/5131/5502861816_5dcc53e12b.jpg" width="374" height="500" alt="" />
Passenger Side View with Bondo

[tsmiley23]

fbaly said:

Next time ill just buy another 3/4 board instead of saving every piece of wood left over.
Woooohooo
What a nightmare
What fun to learn
Make sure you have plenty of clamps
(A BITCH to do)
Tongue Box! What what
IT scares me.
( I hate painting)
The outside will be way better.
what a nightmare
(cheaper then buying them at lowes)
Drilling hahahahah
What a pain in the ass!




You have got to be having a ball!!! You're quotes tear me up

I really do admire your perseverance and am enjoying watching. Hope it's all you dreamed. Please tell us a little about yourself, where did you learn to do this stuff, you really are quite creative and ingenious?

Keep up the good work

Terry

[fbaly]

Well to answer your questions:

First this just started because I wanted an excuse to make something to haul my motorcycle in. So I decided to go all out and make something big. Just because people said I wouldn't be able to do it.


I am having a great time with this project. I am starting to really want to just finish it and start another project.
I have great ideas and ways to make the next one even better.


Where did I learn this stuff.
Well trial and error.
I started with building a small entertainment center and then a year later building another. I ask a lot of questions and I am willing to try just about anything.

I have to give props out to my buds up north because they have been a great help. They are probably sick of hearing about this big project.

Then decided to go ahead and do this.
From one spectrum to the other.

But I can't take all the credit. My girlfriend HEATHER! has been a great help as well. I have been teaching her some new stuff with working with her hands and she has been a real champ. She doesn't enjoy the cold garage but the warm weather is coming. :-)

[aggie79]

Whew! These speed builds wear me out!

Fantastic job on the tear hauler. It looks great and is heck for stout! Thank you for posting pictures.

[H-Balm]

Whoa!
It's like I'm in my garage!

I am working on the same frame model.
You however are working a a faster pace than I....and I started in July!

Good to see! Keep at it!

[fbaly]

Man I started last may i believe.
so no worries take your time.

[myoung]

Very interesting framing details. I don't think I have seen this approach before. Congrats on the excellent build and thanks for posting so many photos.

[fbaly]

If I could start over I would do it differently. The approach or original mind set was to use the wood to screw into.. after skinning the whole project I realized I should have just used the metal screws into the metal. O well something to change for next time.