8.5' X 5' Off Road Benroy

[JeepThing]

First let me properly intruduce myself, My name is Jay and I live in the fraser Valley of Britsh Columbia, Canada. My TV is a Jeep Cherokee and thus the User name JeepThing. My Benroy will be named the Mountain-Tear and will be 8 1/2' X 5' and sit 19" off the ground on 235/75/15 goodyear wranglers on Jeep factory rims.

OK it's late in the game for me now to be entering a build journal, but I thought seeing how so many of you have inspired me to build, I thought I should share a little of my experiences with you and hopefully future builders as well.

First I have never seen a teardrop in person! Never looked inside the galley to see how it's put together and never looked inside the cabin to see how much room there is. But the idea of making my very own personal camper that is light weight; cheap, unique and stirs up the imagination of camping in far away mountain places sold me on the idea.

When looking for and idea to convert my utility trailer into something I could use for camping I came across tiny campers and teardrops. Well the rest is history. I wasn't about to convert my utility trailer I was going to make one of those Teardrop Trailers.

So I started researching what I wanted, and came up with these thing that I needed.
1) Wide enough to sleep two
2) High enough to have the same clearance as my tow vehicle
3) A place to store my (guitar) AKA guns for hunting

So the Benroy off road was the only choice for me.
Finding a frame I wanted wasn't an easy thing as it will need it to be extra strong and the exact dimensions I'll require. So after pricing out different metal shop to put a frame together I found that I could for just about as much money build my own including the purchase of a Lincoln Sp-180 mig welder with a large bottle. I purchased all the metal and welder for under a grand. The shops where looking at around $800 + so for a few bucks more I get what I want and have a NEW TOY.

Oh and as the build goes along another great thing has happened. I now have a legitimate excuse to buy NEW Toys. So the actual build is approximately 40% more the cost of materials. At least I keep telling myself that.

I’ll keep this as simple as I can, I found out early in the game that over thinking is the cause of much delay. A few beers and a good chat with a friend goes much further than sitting contemplating which screw to use or is 5/8 really that much stronger than ½â€

[3822sean]

sounds great .pics would be nice

[kinto]

hi jay,

like you i've been posting to my album but just started a build journal.. about a month in for me.

anyway, yours is looking really nice! great work

also, for pics here you just need to copy the image url & then click the 'img' button above your post & paste the url after that... it will automatically place the /img code at the end. it tends to be easier if you have 2 browser windows or multiple tabs open so you can copy/ paste back and forth between them.

kent

[campmaster-k]

I thought I was the only one who was tape crazy. I have no idea how many i own. Many. I try to gather them into a pile before I start, by the end of the work day they are gone?

[JeepThing]

I started with a few purchases I found on Craig’s list. I was lucky enough to find someone who was going to build a teardrop but was not able to follow through with his plans as he had to move and start a different job. I was able to get a roll of Filon 8.5’ X 17’, two windows and an 8â€

[JeepThing]

The base frame work for the "shell" to attach too is made of 2x6 pine boards with rabbits to allow the floor to drop into. I chose these dimensions because it allowed me to have plenty of wood to screw too as well as being able to use just one sheet of plywood for the floor. All pieces where glued with polyurethane construction glue screwed together and treated with a wood preservative to prevent any chance of rot. The belly of the floor is coated with the black roofing goop as well sealed with flashing caulking at the seams. You can see it up side down, it was caught in the rain and it actually held the rain on it.

[Bob Patterson]

Your frame looks great. I have looked at your album and am impressed with all of your work. Nice deal from your friend on the materials. I like the doors you have. Where did you get them for such a good price?

[JeepThing]

Thanks! I purchased them from an rv dealer, they had the door handles cut the wrong size so they where in the clearance section of the parts store for $99 each . Had to modify each and change the hindges to open the left on the road side.

[Zboom]

Hey JeepThing I looked through your album. Where did you get those doors? The build looks sweet!

[JeepThing]

Thanks! I purchased them from an rv dealer, they had the door handles cut the wrong size so they where in the clearance section of the parts store for $99 each . Had to modify each and change the hindges to open the left on the road side.

[JeepThing]

I painted the frame with an HVLP spray gun. Here you can see the added brackets and reciever hitch, but not the added support to the tongue. I'll have to take another shot to show what it was I did there.

[JeepThing]

Here is a picture of the bottom of the tongue bar with the added bar welded on. It added about 8 lbs. For peice of mind it is worth the weight.

Here you can also see the way I mounted the battery box. I made this box with 1 1/2" angle and covered with Diamond plate Aluminum. I used u-bolts to attach the battery box, so I can remove it easily when I eventually get a diamond plate storeage box. (too much money for now)

The 7pin cord and 12v battery wire run through the added bar for extra protection.

[JeepThing]

Just another view of the part of the frame.

[JeepThing]

After the frame and floor base where finished, I started on the wall, I layed out the idea for the Benroy style walls and had to use two pieces of ¾â€

[JeepThing]

Here you can see the profile, as well as how I had to cut out two pieces of plywood. I choose to make my joining pieces to join above the door opening as this will easily be reinforced with added lumber and cross spars later on. The 3/8th inch notch for the hatch is cut out using a jig saw and both walls screwed together, than I sanded all the edges with a belt sander for a uniform profile. Also the floor frame was cut 1.5" shorter on the width and ¾â€