aggie79 wrote:
I agree. Tell us a little more about the wall and roof construction, please.
I used extremely lightweight normal construction for the most part.
Walls: 2x2 ( 1 3/8 x 1 3/8 ) doug fir. Stiffest wood in that size I could find at Home Depot/Lowes. A bit expensive. I built the frame using butt joints which were glued with gorilla glue and screwed with stainless steel screws.
I then cut out an appropriate-sized piece of 5mm luaun (from home depot) and glued with gorilla glue to the frame. Rib spacing was a bit random, mostly 16".
Roof: mostlly the same as the walls, except the for outside edge I used 2x4s not 2x2s. everything else the same as the walls.
Floor: 1/2" oak (or was it birch) veneer plywood (for a varnished floor). I glued (gorilla) and screwed (stainless) the plywood to 2x2 furring strips (ribs every 2'). since the floor is bolted to the trailer frame, I didn't need the stiffness of the doug fir and consequently could save a few shekels.
After taking it out the first time, we decided that 4'x8' living space was like being in a mars capsule. Practically had to play 'Twister' while moving past each other, or converting the bench seat into the bed for the evening.
I added the sleeping area using a different construction technique. I did a foam-core sandwich with edges of the 2x2 doug fir and facings with the 5mm luaun. the doug fir sticks needed to be ripped down to 1" to match the thickness of the styrofoam I was using for the foam core. I glued the doug fir edges with gorilla glue, no screws. Then cut out a similar shape of luaun (2, one for each side). I glued one sheet of luaun to the frame and let cure. Next I then cut some blue DOW styrofoam insulation to fit inside the frame. Sprayed the luan with water, smeared on the gorilla glue, laid in the styrofoam, sprayed the other luaun facing sheet with water, smeared on the gorilla glue, put the face glue-side down and used weights to 'clamp' the whole thing together.
I also used vacuum bagging using a shop vac on a few of the foam-core panels. Worked 'fine' except the edges did not come out nice at all, so I needed to re-glue and clamp the facing to the doug fir edge. Let's just say a shop vac will work for a few panels, but then will not
The outside is painted with Pettit marine epoxy, I started with 'old salem clear sealer', then easypoxy undercoater, then easypoxy white. I thought I wold need the clear sealer for the luaun, but was not necessary as I have scraps in the back yard that have been outside for 1 1/2 years with no protection whatsoever and they are not delaminating at all.
Insulation is 3/4" plus 1/2" foil-backed polyisocyanurate. Walls are attached with stainless steel take-apart hinges.