I used 1” foam because 3/4” is very hard to find in Canada. I laminated 18mm & 6mm to get to 1”. A bit of sanding with an orbital sander to level things off.
Roof and all interior skins are 3mm. Exterior walls are 6mm.
I deviated from Tony’s design in the galley. Because I didn’t include a headboard/cupboard in the cabin I bumped the galley wall forward so I could orient the cooler the opposite way. And rather than adding 6mm ply to the entire galley interior walls to provide a surface for the d-seal to butt up against, I mirrored the curve to make about a 10cm wide boomerang shaped piece, necessitating the notch in the counter. I think the cooler slider is 28”. Yes, I would do this again. I wouldn’t reduce the thickness of the gusset, not a risk worth taking. I did everything I could to save weight and every little bit helps, hence the boomerang.
They are Vintage Tech doors. They seem fine but at this point are untested.
As far as things I would do differently? Not a whole lot. I might have stuck more closely to Tony’s plans and techniques to avoid rookie mistakes, but I wanted light and I had different priorities than he did so the design needed to change. The 1” skeleton and insulation I would have avoided if I could, it was a lot of extra work. Finally, my biggest mistake was trying an experimental weatherproofing. I originally tried several coats of diluted TB2 followed by primer and paint (both good quality). Seams and screws were handled using thickened epoxy. Trailer is outside but under a lean-to so fairly protected. It didn’t last a winter. Spring time showed checking on the roof curves. So by trying to avoid fibreglass and epoxy, I ended up doing a lot of extra work to sand back to the plywood.
Anyhow, for a first effort I am pretty happy. It looks pretty good, it is strong and safe, and I am confident it won’t leak.
Bret
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