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Trucks, Trailers and Hauling for Shows

New Project Trailer/RV


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  #31  
Old 05-06-2011, 02:58:50 AM
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Default Re: New Project Trailer/RV

Quote:
Originally Posted by Steve Kunz View Post
Looking Good! Nice work!
How fast can you tow it with this 5th wheel draw bar setup?
Standard UK/Europe speeds, Steve, 50mph max on single-carriageway roads, 60mph on dual-carriageway and motorways (freeways)

You also cannot use the outside lane on motorways when towing a trailer.

Peter
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  #32  
Old 05-06-2011, 03:33:30 PM
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Default Re: New Project Trailer/RV

Absolutely knackered!

Got the front and sides on today, starting to look good:









Peter
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  #33  
Old 05-08-2011, 03:08:26 PM
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Default Re: New Project Trailer/RV

Very productive day, in fact the whole weekend has been good, despite some very heavy rain about 4am this morning, but that had dried up by 10am with the breeze and sun.

We have cut and stuck in place both cant rails (the top of each side) and fixed all the roof bars in place. Just short of one single-sided tophat section to make up the second skylight/vent aperture. In the pictures there is a conventional top hat piece just sitting there.

We get a delivery on Tuesday from Aalco so we can finish the roof and start the rear door.ramp.

Also got to square up the chassis on axle stands before we finally fit the GRP roof, which comes on a roll 2550mm wide and cut to your length, 1.3mm thick.


Outside on offside



Outside on nearside



Single and double sided roof sticks



View from ist floor of the house


Peter
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  #34  
Old 05-12-2011, 02:05:25 AM
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Default Re: New Project Trailer/RV

I made up a set of spacers for the lashing eyes this morning, but got brain fade and forgot to allow for the treadplate.

Made a second set up which worked a treat. Each eye is retained by an M16 bolt below which bolts through a 6mm gusset plate in the chassis corner:



Next up was the rear end and the aperture for the door. First off we had to take out the offside corner pillar and re-seat it, this time we put the screws in that we should have done first time round...

The rear has to have some panelling to give some stiffness to that end of the body, so one across the top full width, and one on either side. Before finally glueing and screwing we check diagonal dimensions to make sure we were square:





The corner castings went in OK, but it was a trifle messy with the sealant!



The nearside vertical panel is waiting to go in, so as we have a self imposed power tool curfew at 7pm, that will be done tomorrow. Two right-angle stiffener plates will be fitted up in each corner and across the panel joint.

Peter
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  #35  
Old 05-12-2011, 09:28:26 PM
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Default Re: New Project Trailer/RV

Carried on from yesterday, spent a few hours at the factory then left Rita and the boys to look after things while I came back home.

First job was to put the n/side vertical door panel in place and glued in, that took a while as I couldn't get the closeness of cut I wanted with the circular saw, so resorted to the grinder with cutting disc.



Then I started on fitting the floor outriggers. and quite fortuitously the offcuts from the main honeycomb floor boards were exactly the right size, so just needed the length to be trimmed. Serendipity or what? :whistle:



The new nylon winch rope roller was made up this morning as well, we bought a standard keel roller from Indespension, but the rubber roller was too soft and wouldn't roll with a load on, so we made a new roller out of Nylon and a new pin from brass. The pin was 7/16" diameter, but we found an ebay supplier with some lengths so that was sorted.



The outrigger boards went down OK, the pictured side has three offcuts used as we had them, and that is underneath the toilet/shower so won't be seen.



Lots of threatening clouds and a couple of showers, so had to work under a tarp for most of the day. We have a couple of truck side sheets of heavy PVC/Nylon that we use on the engines, they last almost indefinitely and are totally weather and water proof. One can be seen in the first picture, over the roof rails.

Hope to get the roof on over the weekend, will be doing the wheelboxes tomorrow. The 21mm thickj honeycomb is a good material to work with, but has a slight disadvantage in that you can't screw into it like plywood, but you can bolt through it and use adhesive/sealer to hold it in place.

Peter
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  #36  
Old 05-16-2011, 03:08:06 AM
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Default Re: New Project Trailer/RV

Roof is on and stuck down, capping bolted on each end for now, but we will replace with rivets tomorrow.









Going to get the divider/bulkhead done next, then the drawbridge when the metal is cut.

Peter
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  #37  
Old 05-16-2011, 03:10:21 AM
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Default Re: New Project Trailer/RV

This is a bit out of sequence, but shows the roof rails with the double-sided tape on, and the second picture shows the roof material laying in place.

Roof is held in place temporarily while we drill the holes for the rivets. The cant rail and the mouldings are already drilled, just a case of matching it all up and popping the drill through.

Once that is done, we have to trim the back end of the waste/excess material, then will start removing the protective layer on the double-sided tape and get the roll stuck down, then we can rivet the moulding over the top.





Surprised how much light comes through, we were told that it would allow any light through!

Peter
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  #38  
Old 05-18-2011, 03:12:23 PM
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Default Re: New Project Trailer/RV

All sorts of things happening on the trailer, main items:

Windows have been ordered now, we were going to use the caravan ones that we had, but decided to go for new with laminated glass.

Extrusion for the door opening was replaced by Aalco, they delivered the wrong extrusion yesterday.

Picked up the modified bed/seat frame today and after laying the new floor covering dowm, had a trial assembly to see how it all looks:



Lots to do yet, but real progress being made now.

Peter
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  #39  
Old 05-19-2011, 02:56:27 PM
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Default Re: New Project Trailer/RV

Today's efforts included fitting the seats/beds in properly, plus we got the kitchen unit and floor covering done this evening.





The small cabinet is normally taken off its mounting if you want the full-size double bed (about 6ft X 6ft 6") but for most folks it is big enough with it in place.

The panels on the walls are anti-condensation screens that let air up behind the cushions and stop damp accumulating.

The adjustment needed was 20mm on each side to make the caravan beds fit the trailer. We had 6 pces of Meranti hardwood cut to 20mm X 40mm and screwed them to the walls each side, then screwed the beds and the panels to them.

Peter
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  #40  
Old 05-22-2011, 02:17:15 PM
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Default Re: New Project Trailer/RV

Had a reasonably good day, have tried out a few configurations for the wheelarches/boxes, and after a bit of faffing around with the tape measure, put one together completely and trimmed it up.

We were originally going to get these fabricated in steel, but we had sufficient honeycomb sheet left over to do them both, so that's what we have ended up with.

The inner panel is bolted to the outside face of the main chassis, the top panel is bolted to the side rave extrusion and two filler pieces complete the box, one at each end.

I used some equal angle extrusion to trim the joints as they are a bit unsightly on the honeycomb, and once done they looked quite tidy. I was particularly pleased with the mitres on the corners, they came out really well.








We are going to put a couple of M10 eyebolts into the main chassis risers in the living area, mainly for tying down anything heavy, but will be useful for restraining anything that we want to carry in there.

Peter
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