New build 5' x 12' sleeping 4

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Finished the roof and trimmed the edges

Postby LMarsh » Fri Jun 23, 2017 2:44 pm

Now that the teardrop is at the new house I finished up the roof and trimmed all the edges with the router. It was messy and I might need to hit some high spots with a sander where the panels meet, but overall its moving along. I've been procrastinating ordering the metal from SAF and I wish I had access to a loading dock. I also will probably coat the plywood in some polyurethane, or "the mix" as I've seen recommended in other threads (although I recently read an article about such mixes being ineffective, I might have to try to find that again) as en extra layer of protection in case water ever does get by the outer skin. I haven't decided on an adhesive for the aluminum and I've scoured the forum. I'm going to start a new thread for that.

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Before:
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After:
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So far so good:
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Tow vehicle:
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Last edited by LMarsh on Mon Jan 15, 2018 11:12 pm, edited 1 time in total.
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Re: New build 5' x 12' sleeping 4

Postby LMarsh » Wed Jul 26, 2017 12:37 pm

As always I overdo things. I just epoxied the entire outer wood shell even though it will be completely covered with Anodized aluminum. I basically wanted to seal the wood the best I could just in case water ever got under the skin. I started using "the mix" but I decided polyurethane wouldn't do all that much in the long run against moisture and also the epoxy was actually about the same price, or just slightly more. I've never used epoxy, except gluing stuff, so this as a first. It was a good way to jump in and learn something new because its getting covered up anyway and I don't care what it looks like. Its definitely harder to apply when the plywood is not laying flat, and there are lots of different types of epoxies out there. I just went with an inexpensive type that wasn't too thick. There are also lots of different viscosity types available too. I probably should have used something thinner but a single coat was fine in most places. I tried doing a second coat but then gave up because it wasn't necessary. I'm going to save my left over epoxy and cast stuff in it for the kids or make cool little projects with them. Epoxy is pretty interesting and leaves a super thick smooth glass like surface that's extremely strong. It won't be exposed to UV so it should last pretty much forever and completely waterproof the plywood. I might have to build a woody someday and see if I can make it look really nice. I did get runs and plenty of flaws, but again it doesn't matter. I was surprised how sensitive the epoxy was to mixing ratio, stirring, temperature (even the heat from my hand made it cure quicker in the bottom of the cup, and other factors that made different pots cure at different rates. I did it all on the same day too. Just goes to show how amateur I am at wood working and finishing.

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Last edited by LMarsh on Mon Jan 15, 2018 10:05 am, edited 1 time in total.
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Re: New build 5' x 12' sleeping 4

Postby LMarsh » Thu Jul 27, 2017 9:55 am

Actually I just realized that the reason it went on so thick with one coat was because I had previously put on a single coat of very thin polyurethane. Even though I sanded it off it still kept the epoxy from soaking into the wood. There were a few panels where I didn't apply polyurethane and then I started putting a second coat of epoxy on these spots. Its probably still not completely necessary to do to two coats either way, but it would be easier and cheaper to put that thin coat of polyurethane on first. Unless it effects adhesion.
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Re: New build 5' x 12' sleeping 4

Postby LMarsh » Mon Jan 15, 2018 11:32 pm

Quick update from last fall. I've got the skin on and mostly trimmed off with my router. It's a perfect fit on all the edges now. I've never done it this way before but it was easy and gives super clean edges. I went with Fusor800 as my glue and this stuff remains flexible, is super strong, grabs and holds well to everything, doesn't cost an arm and a leg, and was available locally. It does does skin over a bit quicker than I'd like. After that it appears to cure quickly but actually takes a few days to reach a decent strength. I also used Sikabond from the big box stores anywhere that would also have mechanical fasteners just to save a few bucks and try it out too. The sheets are 5' wide by 12' long and not easy to handle, but not heavy. The remaining ~3" along the bottom of the side walls will be covered with a 4"x1" aluminum angle trim (which was pricey stuff and I probably should have just bought another sheet and cut strips off it).

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After routing:
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Test fitting:
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Routed off edges:
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Crazy hold down technique while adhesives dry:
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Re: New build 5' x 12' sleeping 4

Postby LMarsh » Mon Jan 15, 2018 11:36 pm

I've also done some interior work and wiring, but I'll post those pics later. Ambient air temp was -1 degrees F this morning so I haven't been doing much on the build. :thumbdown:
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Re: New build 5' x 12' sleeping 4

Postby irgod32 » Mon Feb 12, 2018 11:32 pm

LMarsh wrote:I've also done some interior work and wiring, but I'll post those pics later. Ambient air temp was -1 degrees F this morning so I haven't been doing much on the build. :thumbdown:

This is 12' long by 5' wide? What is the height? :thinking:
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Re: New build 5' x 12' sleeping 4

Postby LMarsh » Tue Feb 20, 2018 12:17 pm

The body itself is 12' long by 58" wide on the outside. I haven't decided on the exact tongue length yet because of choosing a tongue box and some other factors. I may just leave it or cut some of the tongue off. I chose the 58" width so that with fenders it will stay under the 80" Federal requirements for additional lighting. It should be just around 79.5" wide when done.

The body height is about 63.5" high from frame to roof edge, then some height for the roof vent. It's currently 13" or so inches from the ground to the frame edge, unloaded. This doesn't include my dropped floor with hangs 6" below the frame.
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