Build Journal: All Aluminum Bare Bones Tiny Travel Trailer

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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Tue Jun 13, 2017 9:34 pm

Ok so I think I've settled on a standard for all my pics thats suitable for the forum.. I went back and changed all the other ones.
Here we go, only allowed three pics per post so I'll do the 8 pics in sequence:
tnttt_22.jpg
cabin from the front
tnttt_22.jpg (90.43 KiB) Viewed 2477 times
tnttt_23.jpg
cabin from the starboard
tnttt_23.jpg (109.58 KiB) Viewed 2477 times
tnttt_24.jpg
close-up of port side slider from the front
tnttt_24.jpg (97.46 KiB) Viewed 2477 times
Last edited by ssuuki19 on Sun Jun 18, 2017 3:12 pm, edited 2 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Tue Jun 13, 2017 9:42 pm

tnttt_25.jpg
underbelly with port and starboard sliders (umm, can you say ice fishing??)
tnttt_25.jpg (95.99 KiB) Viewed 2475 times
tnttt_26.jpg
starboard half-axle mounting approach showing u-bolts and wheel spacer adapter to fit 14" car rims (lens angle makes it look not square)
tnttt_26.jpg (128.99 KiB) Viewed 2475 times
tnttt_27.jpg
another pic of starboard half-axle to show the mounting approach so the sliders can clear
tnttt_27.jpg (127.35 KiB) Viewed 2475 times
Last edited by ssuuki19 on Tue Jun 13, 2017 11:22 pm, edited 3 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Tue Jun 13, 2017 9:45 pm

tnttt_28.jpg
underside of port half-axle to show mounting approach (edit april 2020 - the half axles lasted 22,000 kms or 13,333 miles overloaded)
tnttt_28.jpg (150.16 KiB) Viewed 2471 times
tnttt_29.jpg
underside of trailer tongue to show approach to strengthen and triangulate (not finished yet)
tnttt_29.jpg (156.67 KiB) Viewed 2471 times
Last edited by ssuuki19 on Thu Apr 09, 2020 7:33 pm, edited 2 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Small Travel Trai

Postby ssuuki19 » Tue Jun 13, 2017 11:06 pm

dancam wrote:Whatever bedliner product you choose to use make sure the smell eventually goes away. Some stink when hot for quite a while.

During' this build journal I am going to report what I've done/wrecked today. The idea about using truck bed liner on the interior was discarded for the voc reason and its weight, although I found a supplier willing to do it. Was totally loving the idea of aluminum/xps/bedliner sandwich for strength, rigity, and waterproofness. It seems as usual, gonna end up building heavy (who was the nutbar who threw out 600lbs?!?, oh yea that was me :o ) but still aggressive on the bare bones weight. I have been 'stalling' taking it to the scale. No more stalling, we will get a baseline weight after the weekend festivities and whatnot.
Last edited by ssuuki19 on Mon Jul 03, 2017 12:10 am, edited 2 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby dancam » Sat Jun 17, 2017 1:01 pm

Nice to see this starting back up again :)

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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Tue Jun 27, 2017 10:59 pm

Acoustic insulation panels have arrived, haven't un-crated them yet.
Today the trailer tongue mounting points were beefed up with stainless hardware (so my novice cold welds are redundant, ahem). A 1000lb boat winch was installed at the front of the tongue, and three eye-hooks were installed at the front bottom of the cabin. With a rope through the eye-hooks and a carabiner connected to the winch the cabin can now be pulled onto the trailer just like a boat. To offload, 4 spring hinged tie-downs will be used on the rear end. With all 7 of these tie down points the cabin can now be offloaded by tying to a tree or another car hitch, anything stationary, and it can be carried by 4 ppl with rope loops. I dream about offloading it onto a layer of straw bales when its stationary for awhile.
Anywho, heres the pics for the day. Enjoy!
tnttt_30.jpg
three eye hooks at the bottom of the front
tnttt_30.jpg (105.95 KiB) Viewed 2333 times
tnttt_31.jpg
winch mounting approach, rims cleaned up
tnttt_31.jpg (151.56 KiB) Viewed 2333 times
tnttt_32.jpg
current state of affairs on the trailer - note the 4 stainless steel bolts on the tongue vertices (5th one hidden by the winch)
tnttt_32.jpg (148.1 KiB) Viewed 2333 times

Oh I forgot to mention one thing... that handle on the winch is perfect for moving the trailer as its off to the side and its laterally strong (tried to bend it in a vice) but pivots a bit in freewheel mode, but you can lock it either direction for upgrade pulls and downgrade pushes (driveway is a downgrade). Now the trailer has a 'tongue handle' :thumbsup:
[Edit: broke the direction pin bolt, drilled it out and replaced it with a bigger bolt, haven't lubed it yet]
Last edited by ssuuki19 on Sun Aug 13, 2017 10:23 pm, edited 3 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Wed Jun 28, 2017 9:54 pm

So today for the first time, the cabin section was winched onto the trailer. It worked quite well. As the winch got taught on the caribiner the trailer frame shored up against the tree stump piece that you've seen in the pics. And the cabin section slid like a slider, this is great news. Might put carpet on the trailer frame edges. Here are the first three pics in the sequence:
tnttt_33.jpg
closeup of the winch
tnttt_33.jpg (97.6 KiB) Viewed 2285 times
tnttt_34.jpg
first test of the winching approach
tnttt_34.jpg (113.43 KiB) Viewed 2285 times
tnttt_35.jpg
the dang thing just crawled its way on to the trailer
tnttt_35.jpg (119.26 KiB) Viewed 2285 times
Last edited by ssuuki19 on Sun Jul 02, 2017 11:07 pm, edited 4 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Wed Jun 28, 2017 10:10 pm

So what I learned today is by blocking the trailer at pretty much the right height, the weight transfer to the trailer frame was quite seamless. The rails did have a 'self aligning' effect and from there it winched really well, I don't think the 1000 pound winch was pushed too much. But I might try some 2:1 setups to put less stress on it. You can see in the pics that I forgot to 'centre' the caribiner so the winch strap was a bit out of alignment, but still worked fine nonetheless.
So another obstacle overcome! There was a distinct possibility that the exposed bolt heads from the stainless steel bolts on the frame would line up with the underside aluminum rivets, but luckily this was not the case, so there were no scraping issues (whew, the clearance tolerance right now is pretty much nil). Raising the height by a few mm will take care of any hangup issues in the field, I figure. Here is the rest of the successful winching:
tnttt_36.jpg
aaand there we go (actually in the field it can go a foot to two feet more to get the tongue weight right)
tnttt_36.jpg (116.91 KiB) Viewed 2282 times
tnttt_37.jpg
and another pic of the completed weight transfer to the trailer
tnttt_37.jpg (106.31 KiB) Viewed 2282 times
tnttt_38.jpg
ready to roll, boat style! (well with some tie down hardware tbd)
tnttt_38.jpg (118.88 KiB) Viewed 2282 times
Last edited by ssuuki19 on Mon Jul 03, 2017 12:25 am, edited 6 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Wed Jun 28, 2017 10:16 pm

Insulation arrived at build site. Time to make some big decisions and get the windows and doors mounted! Got my rivet gun back this past wknd so pretty much ready to roll.. er... rivet.
tnttt_39.jpg
time to take a look at these sound dampening insulation panels! pics soon
tnttt_39.jpg (109.43 KiB) Viewed 2280 times

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby crpngdth2001 » Thu Jun 29, 2017 8:13 am

Looks great so far!


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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Sun Jul 02, 2017 11:14 pm

Much appreciated!, I hope ppl who read my thread when I thought I could do it in a year are still reading my thread like I do from for re-edits. You see, this machine might actually do what it sought to do, at least no deal breakers are seen today.... soooo its all looking like there aren't any show stoppers in the rest of the build, there was one last gaggler - the cargo door hinge. [Edit: found 3" .061 aluminum piano hinge no worries, all is well, see pics below somewhere]
Last edited by ssuuki19 on Fri Aug 18, 2017 7:12 pm, edited 2 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
User avatar
ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Sun Jul 02, 2017 11:23 pm

Should I do the moon window at the front, or the giant full sized rv passenger door first?

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
User avatar
ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Tue Jul 04, 2017 8:59 pm

Did the front window first, it was tougher because the 1/8" .375" grip alum-alum rivets don't have much pull when you set them so I used a lot in order to compress the butyl tape. On the inside 4 triangular notched brackets were added to the corners. Honestly it just sort of worked out well, I more than doubled the rivets to compress that ring, and have the butyl tape pushed out completely around the perimeter. The rivets along the top and bottom go through the 1/8" square tube so the window is set solid. Rivets were each dipped in sikkaseal, as well as the back of the brackets (using a toothbrush). The sealant acts like a glue too, its great to hold pieces in place while drilling, etc. So window 1 done, three more and two doors to go. Tomorrow, the excess butyl tape will be scraped off flush, and a bead of sikka-seal will be done on both sides to complete the install. Heres the pics:
tnttt_40.jpg
inside view
tnttt_40.jpg (87.88 KiB) Viewed 2100 times
tnttt_41.jpg
close-up of bracket idea
tnttt_41.jpg (82.42 KiB) Viewed 2100 times
tnttt_42.jpg
window from the front, had to move rivets up and down best I could do was make it symmetrical
tnttt_42.jpg (115.61 KiB) Viewed 2100 times

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
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ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Thu Jul 06, 2017 9:01 pm

So today two of the Lil' Bear crankout windows were installed. These windows were pretty straightforward to install because they were pre-fit, just to tolerance. The butyl tape is amazing, its like playdough you can re-use the squishout and whatnot. A 1/4" bead of sikkaseal was added to the inside corner perimeter of the windows because it will help when sealing the inside. Standard 3/16" alum alum rivets, I decided to add horizontal rivets on both windows to ensure the butyl tape squished out, again, its awesome stuff, but I'm still figuring it out. The 3/16" rivets have a pretty sweet amount of pull to them - they were able to squish the butyl tape, just fine. I love that sound now, when a good pop rivet goes in. All went well, gave the windows a water wipe, they are easy to clean. Took some pics:
tnttt_43.jpg
first lil' bear crankout window install with butyl tape, sikkaseal, rivets
tnttt_43.jpg (105.39 KiB) Viewed 2049 times
tnttt_44.jpg
the two driver side windows installed
tnttt_44.jpg (79.51 KiB) Viewed 2049 times
tnttt_45.jpg
this is the view from the galley (cargo door opens up to make umbrella in rainy times)
tnttt_45.jpg (101.94 KiB) Viewed 2049 times
Last edited by ssuuki19 on Fri Jul 07, 2017 9:23 pm, edited 4 times in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
User avatar
ssuuki19
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Re: Build Journal: All Aluminum Bare Bones Tiny Travel Trail

Postby ssuuki19 » Fri Jul 07, 2017 8:32 pm

So today the final window was installed. Pretty much same method - butyl tape, sikkaseal, rivets. Seems to work pretty great with the aluminum rivets. I'm getting faster at it too. Ooh almost forgot, today the aluminum piano hinge was purchased and brought to the build site. Here's the pics for the day:
tnttt_46.jpg
read that if you put similar windows on both sides it creates the 'illusion' of space
tnttt_46.jpg (85.16 KiB) Viewed 2010 times
tnttt_47.jpg
just a nice pic of the Lil' Bear 30" window
tnttt_47.jpg (120.92 KiB) Viewed 2010 times
tnttt_48.jpg
the view from the galley towards the door (next up...)
tnttt_48.jpg (97.68 KiB) Viewed 2010 times
Last edited by ssuuki19 on Sat Jul 15, 2017 5:30 pm, edited 1 time in total.

How does sealant get on my triceps and then my car seat?? more than once??
Aluminum is almost as fascinating as wood.
Link to my build thread: 4 1/2 x 9
User avatar
ssuuki19
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Posts: 170
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