Hello! This is my first post here, and I'm not entirely sure how best to organize this. In April 2024, I really wanted to build a camp trailer for our family of 4, and had (misguided?) ideas of it being off-road capable. What I ended up with was a pretty great build for us, but there were definitely some compromises along the way.
Mainly, I just want to share my build experience with a community who thinks this kind of thing is interesting. So maybe I'll just start at the beginning..
I started with a bunch of hand drawings and then built some models in the basement out of 2X4's and plywood. I wanted to keep the total weight under 2500lb fully loaded, so this meant it had to be as small as possible, while still being comfortable. I also wanted to keep it under $20,000. Once I had a good idea of how I wanted it laid out, I started modeling it up in CAD. CAD is great, but it doesn't really do anything magic, you still need to know what you're going to make everything out of and what components you are going to use. It's actually a lot more work in the front end, but really amazing to have as the build comes together if you spend the time. Anyway, it was time to figure out what to build it out of.
I wanted to use fiberglass - foam sandwich panels with aluminum extruded corners that are thermally isolated. This was the hardest thing to source by far, I spent a lot of time on the phone with companies that didn't really want to talk to me. I finally was able to secure an actual quote for panels made in Canada, from an outfit called CPT "Composite Panel Technologies". They ended up working out, but it was a huge pain to get information out of them about the simplest questions, I was nervous a few times that they were never going to show up, but it ended up being fine if I called them enough! They actually included all the Sikaflex 252 I would need and some other nice details in the end.
Now that I had the main building material chosen, I started researching the actual trailer. I had it in my mind that I wanted it to be aluminum for weight savings, but after talking to a lot of trailer builders, it seemed pretty clear that a steel trailer of this size was not really any more heavy, unless the aluminum trailer is built very carefully and heat treated after welding etc. I talked to a bunch of trailer builders, and finally chose someone to make the frame, but that fell apart in the end, they just were not able to get it done in time and didn't want to do anything custom. At this point I decided to weld up my own trailer, using Timbren suspension (which I don't love now that I have it).
With the trailer and camper material chosen, I was able to refine the CAD. I modeled every detail I could, including the Timbren 3500 axle-less suspension and all the other trailer parts. I chose a battery system (more on that later), a fridge, an AC, a heater, propane tank mounts, sink and water system, composting toilet, stovetop, windows, and door among other things. With all this modeled and looking good I started building!
The above is the Solidworks model. I ended up with Arctic Tern Door and Windows which have been really awesome, although the cost is a bit insane. The lights and trailer hardware / fenders are from e-trailers, and the fridge/stovetop are dometic. I don't have solar on there yet, but they will be Rich Solar MEGA 250 panels I think.
The general layout can be seen in the CAD, there are 2 benches with storage underneath, and a large table that seats 4 average size people easily. I really wanted a spacious place to hang out and play cards with the 4 of us, and it was a bit tough to fit in there. the total outside dims are 10'6" X 6'.
The table is held down with magnets, this works way better than I thought it would! It lays down to complete the center bed, and one kid goes up in the bunk, and one kid goes under with the dog ;-). Maybe not the best arrangement for 4 adults, but pretty fine for a couple of teens.
Here are some images of parts when they arrived at my house. Poor UPS guy....
This is all the steel for the frame in the shop!
8X 230ah Lifepo4 cells for the battery
All the panels, glue, and corners before I cut them
That is probably enough information in one post? I don't have a huge number of photos of the build process, but a few and I'll follow up with more on the build if people are interested.
Thanks for having a look!
Mainly, I just want to share my build experience with a community who thinks this kind of thing is interesting. So maybe I'll just start at the beginning..
I started with a bunch of hand drawings and then built some models in the basement out of 2X4's and plywood. I wanted to keep the total weight under 2500lb fully loaded, so this meant it had to be as small as possible, while still being comfortable. I also wanted to keep it under $20,000. Once I had a good idea of how I wanted it laid out, I started modeling it up in CAD. CAD is great, but it doesn't really do anything magic, you still need to know what you're going to make everything out of and what components you are going to use. It's actually a lot more work in the front end, but really amazing to have as the build comes together if you spend the time. Anyway, it was time to figure out what to build it out of.
I wanted to use fiberglass - foam sandwich panels with aluminum extruded corners that are thermally isolated. This was the hardest thing to source by far, I spent a lot of time on the phone with companies that didn't really want to talk to me. I finally was able to secure an actual quote for panels made in Canada, from an outfit called CPT "Composite Panel Technologies". They ended up working out, but it was a huge pain to get information out of them about the simplest questions, I was nervous a few times that they were never going to show up, but it ended up being fine if I called them enough! They actually included all the Sikaflex 252 I would need and some other nice details in the end.
Now that I had the main building material chosen, I started researching the actual trailer. I had it in my mind that I wanted it to be aluminum for weight savings, but after talking to a lot of trailer builders, it seemed pretty clear that a steel trailer of this size was not really any more heavy, unless the aluminum trailer is built very carefully and heat treated after welding etc. I talked to a bunch of trailer builders, and finally chose someone to make the frame, but that fell apart in the end, they just were not able to get it done in time and didn't want to do anything custom. At this point I decided to weld up my own trailer, using Timbren suspension (which I don't love now that I have it).
With the trailer and camper material chosen, I was able to refine the CAD. I modeled every detail I could, including the Timbren 3500 axle-less suspension and all the other trailer parts. I chose a battery system (more on that later), a fridge, an AC, a heater, propane tank mounts, sink and water system, composting toilet, stovetop, windows, and door among other things. With all this modeled and looking good I started building!
The above is the Solidworks model. I ended up with Arctic Tern Door and Windows which have been really awesome, although the cost is a bit insane. The lights and trailer hardware / fenders are from e-trailers, and the fridge/stovetop are dometic. I don't have solar on there yet, but they will be Rich Solar MEGA 250 panels I think.
The general layout can be seen in the CAD, there are 2 benches with storage underneath, and a large table that seats 4 average size people easily. I really wanted a spacious place to hang out and play cards with the 4 of us, and it was a bit tough to fit in there. the total outside dims are 10'6" X 6'.
The table is held down with magnets, this works way better than I thought it would! It lays down to complete the center bed, and one kid goes up in the bunk, and one kid goes under with the dog ;-). Maybe not the best arrangement for 4 adults, but pretty fine for a couple of teens.
Here are some images of parts when they arrived at my house. Poor UPS guy....
This is all the steel for the frame in the shop!
8X 230ah Lifepo4 cells for the battery
All the panels, glue, and corners before I cut them
That is probably enough information in one post? I don't have a huge number of photos of the build process, but a few and I'll follow up with more on the build if people are interested.
Thanks for having a look!