Funny how these things go in spurts. After about ten days away from (the future) Campy McCampface, I got a lot done over the weekend.
I got a chance to stand up the walls with a front stub wall and a proposed front bump-out...
...and wow, does this thing look huge inside. I want to make the front a little more aero, and while a curve would be pretty, I think a straight-line panel might make a good place for a solar panel. This angle looks promising:
After the test-fit and dreaming session ended, it was time to get more realistic. You'll notice in the top photo that my garage is VERY short. I have been thinking about how high I could make the trailer without hitting the ceiling, but had totally underestimated the height of a Fantastic Fan, which is about 4 1/2" inches. So I'm going to have to take 2" off the sidewalls. Not going to cry over it, though.
I had been going back & forth about how to hold the foam to the floor, and decided to make a 1" square cleat for the foam to wrap around.
I made the cleat by ripping and Gorilla Gluing some scrap 1/2' ply from the floor...
Looks like it'll fit tightly.
Note: You all probably already realize that running a router thru foam creates a pink foam blizzard. Easy to carve, but whatta mess.
To hold the top to the trailer base, I cut a scrap 1"x1"x2" piece of cleat and doubled it on the foot, and then capped it with a 2"x2" top:
A T-nut will go on the top and stainless bolts will hold the camper from the bottom. Hope 16 of these are enough!
The foam will have to be notched to accommodate the foot.
Once I figured that out, I took the whole deal apart (all tape and skewers) and set upon waterproofing the floor. In removing the floor from the trailer I managed to break off the back 2' of the floor, but that's no biggie, I'll reglue and reinforce that joint when it's time to start assembling. I waterproofed with The Mix...
...first a few coats of 25% urethane to 75% paint thinner, then upping it to about 50/50 for another two coats on the bottom (only put one coat on the top, which I expect to stay dry.) Anyone think that's good enough?
Once that was reasonably dry, I glued and screwed the front cleat to the floor, which is drying right now.
Oh yeah, in the downtime I replaced and tested the trailer light controller on my minivan.
Not a bad weekend overall! Any advice from the Olde Masters?