Building the Turd

climbingxj

New member
I said I'd never do it, but somehow I took a tent trailer home on Monday. It's a 1978 Lionell, it's a pile of crap, and my wife has named it the turd. How in the world did I end up in this situation? Here's a little background.

The wife and I will be spending about four weeks this summer travelling throughout Alberta and BC climbing and hiking. Originally I planned on doing what I've always done, packing things into the jeep, sleeping in a tent, and having fun. The more I thought about it though the more I realized I was growing sick of two main aspects of camping. The first is organization. I like to keep all my climbing and camping gear organized, and whenever I'm on the road for a couple of weeks things seep to slowly get less organized, I needed to come up with a system to change that. The second thing I'm sick of is the hassle of cooking while camping. Coolers aren't ideal for keeping things cold, dealing with leftovers is a pain, food prep on a picnic table can be annoying, you get the idea. So I had two requirements: a cooking space and an organizational system.

So I started out wanting a small expedition trailer, then the more I thought about it I wanted to keep the gear in the jeep for convenience, and cook in the trailer, why not a teardrop trailer? Then I could sleep in the thing and save the hassle of setting up a tent. Then I could set up a base camp at a campgroud, and head out for daily trips. If we wanted to head to the back county we'd leave the trailer behind and take off in the jeep. I thought some more, and figured I'd rather a small trailer with a bed and kitchen, but more room than a teardrop. So I decided I wanted a trailer that's about 10' long. Buying a new trailer is out of the question, so I decided to build my own. After reading a pile of build threads and doing some research I decided I wanted to begin my build with a pre-built platform. I learned how to weld years ago, but I don't own a welder right now, and by the time you factor in the cost of steel for the frame, a new axle and suspension components, and registering it with a VIN, I was pretty sure I would be able to find a trailer of some sort for cheaper, and then just build my trailer on that frame.

Well on Sunday night I found my potential platform, and by lunch time Monday my wife and I were the proud owner of a 1978 Lionell tent trailer, and $350 poorer.

Whole Trailer collapsed.jpg
Trailer set up.jpg

The basic plan for this is to turn it into a 10' hard sided camper that contains a comfy bed, a kitchen with a small fridge, running water, propane stove, and electricity (batteries charged using solar power). It has to be usable by the beginning of June, so I'm planning on having the trailer built and livable by then, but may not have running water, batteries or solar panels in it until July. We'll see how finances and spare time work out.

I thought it would be nice to start a build thread in order to document the experience for both myself and others. I'm going to make a few mistakes, learn a bunch, and have a bunch of fun along the way. I love tinkering and building things, and I thought that others may be able to learn from my experiences and mistakes. It would also be nice to be able to have a place to post any questions I may have along the way and get some help if needed as this is the first time I've built a trailer.

It's time for tear down to begin...
 
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climbingxj

New member
Canvas partially gone:

Trailer with first panel down.jpg

Canvas Gone:

Trailer all pannels gone.jpg

then started to remove the interior components. The propane fridge, heater, and stove all apparently work. I'm going to re-finish the stove and re-use it, and try and sell or give away the fridge and maybe a few odds and ends to try and keep usable items out of the landfill. Gotta love the puke green carpet and linoleum...

interior at begining of tear down.jpg

I found a few surprises hiding behind the cabinets:

horseshoes.jpg
special K.jpg

I had taken everything out pretty gently up to this point, but the roof was more difficult than I thought to get off, and was surprisingly heavy. So with a little help from a BFH and the wind, I got er down:

roof partially down 2.jpg
roof fully down 2.jpg

Then the sides came off:

Trailer all sides down poor light 2.jpg

Taking the deck off was a lot more work than I anticipated. The heads fasteners that they used to hold the deck down were under the surface of the plywood and not visible in any way. I'm not 100% sure, but it's almost like they put down a first layer of 1/4" ply, attached it to the frame with the fasteners, than glued another layer of 1/4" ply on top of the first one. None of the fastener heads were visible on the surface of the plywood (after ripping the linoleum off of course), and they appeared to be driven right through the frame; there was no way to free them from underneath. I ended up digging up each fastener head with a claw of a hammer and a sledge, and then after discovering that they weren't going to budge using my cordless drill, I ground the heads off. It was a little laborious, but worked fine.

deck partially removed - rear view.jpg
deck removed front view.jpg

It's down to the frame now. I'll spend some time tomorrow afternoon and on the weekend cleaning and getting old paint and rust off the frame, and then prepping for paint and painting it.

I'll post some progress pics in the next few days, and share a little of my vision for the trailer, including some drawings and my plans for construction.
 
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oldone

New member
Interesting...

Being a brilliant mechanic, I, too, can take things apart...getting it back together is a whole "nuther" ballgame...

Good luck with your build...
 

oughtsix

New member
Cool project. It looks like the bed framing is bent in front of and behind the wheel wells... but it looks like both sides are the same. Are those factory bends? Do you know what function they served?

I know the previous floor was just plywood. Are you going to seal the new floor before installing it? How? Have you heard about Raptor DIY spray on bed liner? It seems to get good reviews. http://www.amazon.com/Raptor-Truck-Bed-Liner-Black/dp/B002ANVF5E/ref=cm_cr_pr_product_top

You will also need their $20 spray gun.
 

Arlo

Adventurer
Let me ponder:

The title of your book sounds like "Zen or how I got involved to love a VIN"? :elkgrin:

Please have a look first inside the hubs! :coffee:

But it's a good starting project for sure. :)
 

climbingxj

New member
Interesting...

Being a brilliant mechanic, I, too, can take things apart...getting it back together is a whole "nuther" ballgame...

Good luck with your build...

Thanks! Getting everything back together and well built will be the hard part, I'm looking forward to learning a lot along the way.
 

climbingxj

New member
Cool project. It looks like the bed framing is bent in front of and behind the wheel wells... but it looks like both sides are the same. Are those factory bends? Do you know what function they served?

I know the previous floor was just plywood. Are you going to seal the new floor before installing it? How? Have you heard about Raptor DIY spray on bed liner? It seems to get good reviews. http://www.amazon.com/Raptor-Truck-Bed-Liner-Black/dp/B002ANVF5E/ref=cm_cr_pr_product_top


You will also need their $20 spray gun.


They are factory bend. I'm not 100% sure on the purpose. there would have been more than enough clearance for the tires even without the bends, so I suspect that it may have to do with increasing the structural integrity of the frame. the leaf springs mount to the beam that's sandwiched between the two cross beams that are bent. That's my best guess anyways.

Thanks for the tip on the Raptor DIY bed liner. I'll look into it. At this point I'm thinking of a combination of fiberglass (I'm going to use tongue and groove plywood and fiberglass the place where sheets come together, after gluing them as well), and I was thinking of using an oil based floor paint. I've used it on a lot of high traffic floors before and it's stood up to abuse really well. I'm not sure how durable it would be under a trailer though. sounds like the bed liner is an option as well. Any other idea's or thoughts would be appreciated!
 

climbingxj

New member
Let me ponder:

The title of your book sounds like "Zen or how I got involved to love a VIN"? :elkgrin:

Please have a look first inside the hubs! :coffee:

But it's a good starting project for sure. :)

:D Nice title suggestion!

Ya, the axel may need a little love. I'm gonna pull things apart this weekend or early next week and see if everything is in good shape.
 

Arlo

Adventurer
The basic plan for this is to turn it into a 10' hard sided camper that contains a comfy bed, a kitchen with a small fridge, running water, propane stove, and electricity (batteries charged using solar power). It has to be usable by the beginning of June, so I'm planning on having the trailer built and livable by then, but may not have running water, batteries or solar panels in it until July. We'll see how finances and spare time work out.

Well, less than two months to go! Sounds like an ambitious plan A! :Wow1:
What about plan B? :sombrero:

Nevertheless keep the horseshoes! :coffee:

I need more than a year to get a simple off road trailer ready for the road carrying a tent on top.
It's the small things that cause problems! :wings:
 

oughtsix

New member
I like the fiberglass idea but I would recommend fiberglassing the whole underside of the plywood. I can't quite envision how you would accomplish this then flip the whole piece over? Maybe screw a couple 2x4 across the two pieces?

Glue joints on tongue and groove plywood seams isn't very strong. I would try to get the joint as close to a cross brace as possible. Polyurethane glue is a very strong waterproof wood glue. Wipe the joints with a damp rag first, the moisture helps it cure and makes for a stronger joint (the directions on the bottle recommend this)

I might consider using the bed liner on the frame and the underside of the floor then mounting the floor to the frame before the liner is fully cured... kind of glueing the floor to the frame. I don't believe you would have expansion issues with the plywood.

The fiberglass epoxy is a good strong sealer on wood without the fiberglass; but the fiberglass will make everything stronger.

You might consider making the floor a little oversized then trimming it to the frame with a flush trim bit on a router after the floor is mounted to the frame. I would make sure to seal the edges of the plywood well weather you use fiberglass epoxy, bed liner or something else. fiberglass epoxy should penetrate into the plywood edges well.
 
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Expedition Essentials

Active member
Look into a product called deck restore: I am using it on the underside of my floor, it is a sealer of sorts, formulated for wood vs Bedliner may be a better option for you!
 

TheThom

Adventurer
The floor is commonly discussed and there are lots of ways to do it. I'm rebuilding a PUP I used CPES epoxy sealer on both the top and underside. The underside was also covered with roll-on bed liner and the top was covered with stain and floor polyurethane/bed liner depending on which part.

If you're interested the link to the build thread is in my signature. Good luck! I've been where you are!
 

Martinjmpr

Wiffleball Batter
The only recommendation I'd make is that if you haven't done so already, register on the forums at the Teardrops and Tiny Travel Trailers forum. They are a wealth of information on how to build your small trailer, how to do things like exteriors, frames, finishes, etc. They've been an invaluable asset to me and the wife as we re-build and upgrade our home built (but not by us) teardrop.
 

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