Build Journal for Atomaker's Teardrop Number 2

[atomaker]

After a few weeks of gathering various bits and pieces, including a Dexter Torflex #9, I started cutting steel today.

I kind of fell into the build of my first teardrop, a Cubbie that someone else had started and couldn't figure out. It came to me very inexpensively, with the HF frame assembled, the axle set back and the outer walls cut out. It took about three months to finish. I will toss up some photos when I figure out how, by the way.

One of the very best things that happened to me during the build process was a chance to meet Grant Whipp of Lil' Bear. His seemingly unlimited patience and knowledge inspired me a lot, and he will be my prime supplier for this one as well. TD2, which I have tentatively named Legolas (because of his upcoming journeys with my tow rig, a Honda Element named Gimli), will be based on the Modernistic/Cub style, and I will be using Grant's profile and his frame design as well. I'm a pretty fair fabricator, but I'm still perfectly willing to stand on the shoulders of giants like Grant to make sure it all comes out well.

The frame got cut out today using my new tool, a HF hand-held band-saw. Yeah, I'd like to have a Milwaukee, but I'd rather spend the money on trailer parts.

Per Grant's frame layout on the tracing i got from him, the frame is 1.5" X 2.5" rectangular tubing. He recommended .095 wall thickness, but my local steel yard would have had to S/O it, but they could only supply 14 Ga. and I wanted to be able to weld stuff right to the frame. It will be a few pounds heavier, but I won't have to keep looking in the rear view mirrors to see if I am still towing anything other than the tongue

It's supposed to be 42 degrees outside today in Ashland, and since I store wood pellets in my workspace, I kind of have to weld outside; we lived through a house fire once already, and I don't recommend it. Once I get the axle and the tongue wheel on it, the frame will be reasonably portable, and I can bring it inside. Home Depot in nearby Phoenix, Oregon, was happy to order 4x10 AC Plywood for me, and the price was really reasonable, so after i get the frame built and the wiring sorted, I'll move on to that part.

Cheers!

[KCStudly]

Sounds like a good start!

Re: posting pictures, Folks around here do like pictures! I just happened to have given my take on posting pictures in another thread this evening, 3rd post in the "Ruby Red" build thread located here: http://www.tnttt.com/viewtopic.php?f=50&t=49088.

Good luck!

[synaps3]

Welcome to the forums! I look forward to seeing your progress.

[atomaker]

So Sunday went really smoothly, and by 5:30 I had the bottom of the frame welded, the tongue on and the diagonals in place. The rear stabilizers are on, the tubes for the wing tables are in place and the axle is tacked in place, allowing me to roll the trailer into the garage just as the snow started to fall.

[atomaker]

Tonight i welded some tabs onto all the cross member intersections which i will use to secure the floor to the frame using "Torfloor" bolts like the ones i used to use to fasten planking to flat bed semi-trailers. cut the tongue to final length and drilled two of the four holes for the 1/2 inch grade 8 bolts. I have wood coming tomorrow from my favorite local lumber yard, Norton Lumber in Phoenix. They got me 4 x 10 ac 3/4 plywood for a great price, and will deliver it, some more 3/4 AC ply, the 1/8inch Birch for the inside and Luan for the outer shell.
Grant priced my order for the trim, galley hinge, windows, latches, etc. and will bring it all to Oregon when he comes north on other business in a couple of weeks. This is going much faster than the last one. Harbor sales put my ship date for the aluminum sheet out to the 9th of March, which is fine, since I don't know what I'd do with it right now. The galley will be one of the last things, and it will all be pod built so i can take it in and out like I know i will. I realized i was tired when the welds started to get crooked because the frame was rolling out into the driveway because the stick had moved out from behind the wheel, and decided to call it a night. looking forward to 20 some-odd hours of productive work over the weekend. I'll load more pictures soon

[aggie79]

Wonderful start on your new frame.

BTW, I'm jealouse - wish I had welding equipment and knew how to use it.

Take care,
Tom

[atomaker]

Saturday, March 3rd finally gave me some sunshine! First off, the frame got the angle grinder with a wire brush and then I brushed on some primer made for semi-rusted metal, just because the frame will never see the light of day again, and I think that brushed on primer is better than rattle can. Next, I ran the 120v and 12v harness along the side of the frame and deadheaded it above the rear axle. I'll place it and shoot it through the floor later, when I have decided where is gonna come up into the galley.

Finally got to the the cutting of the side walls! Cut just outside the line on one side and sanded down to it partway when my 20 year old Wen belt sander burst into flames! Unplugged it quick like a bunny and tossed it into the driveway.

Too much excitement

A quick trip to Ashland Hardware for a replacement and a couple of 40 grit belts, and I was back at it. The new Craftsman belt sander is like a Ferrari compared to the old one. Once the profile was perfect, I got out the router and my deep carbide edging bit and copied the shape onto the other side.

Set up the next series of cuts for the floor, and immediately cut one precious piece of 3/4 ply too narrow by exactly one inch

One problem with building a 5 x 10 is that it wrecks a lot of plywood, since you can really only use about a third of the sheet. Oh well. Like it's the design's fault I screwed the cut up

I used a new kind of elastomeric sealer for the underside. It's water based, doesn't smell too badly, cleans up with water and it dried completely in about an hour. I will get the name and a picture when I post again tomorrow.

So I've gone from a pile of steel to a rolling frame with sides and floor cut out in about 26 hours. Not bad for an old fart.

[CHUNKYMONKEY]

I am curious which aluminum sheets are you getting from Harbor sales?

[atomaker]

I'm getting two sheets of 4x10 .040 in Heron Blue, one sheet 5 x 12 in white and one sheet 5 x 10 in white. it should ship on the 9th.

Cheers!

[atomaker]

So I got the sides up and the interior birch plywood partially cut out today, along with the beginning of the framing for the "Stealth" Tongue box. What I've done is to extend part of the forward curvature straight down to an extended part of the floor. the width is only 48", which will let the cool curve of the Modernistic design show, while giving me a ton of room for the battery, wiring and a little compartment and shelf i have in my head.

I'll have to isolate the battery from the rest of the compartment; I can't afford the Optima deep cycle that I really want, because they off-gas very little, if at all. The battery compartment will be vented and gasketed to keep it away from the potential arcs the 12V switches might generate.

Once again i found myself loving the HF pocket screw jig. The integrated clamp makes it really fast to change positions, and, along with the Titebond 3 wood glue, will keep all the joints tight.

[atomaker]

Here are some more pictures as promised.
Here is the undercoating i used. It doesn't smell, applies easily and cleans up with water.


Here you can see the beginnings of the "Stealth" tongue box.

The Supervisor's chair. Occupant changes without notice.