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Trucks, Trailers and Hauling for Shows

New Project Trailer/RV


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  #61  
Old 07-01-2011, 02:29:38 AM
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Default Re: New Project Trailer/RV

Hi Mark:

We are just getting the big moulding (molding) for the bathroom vanity unit cleaned up and reinforced before mounting it up, that will be done before we build the bathroom/shower cubicle walls in. The shower tray fits underneath and the cassette toilet over the other end, so it's all integrated.

The cassette toilet is waiting for installation drawings from Thetford before we cut the outer wall for the cassette access door, don't want to put it in the wrong place!

Once the bathroom walls are in place, we can then look at water piping/routeing and also the electric/gas water heater, which also needs a hole cutting in the side, and the water access point which needs yet another hole...

If we get along sufficiently well this weekend, I'll get some pictures, don't want to post unnecessarily.

Peter
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Old 07-02-2011, 03:10:18 PM
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Default Re: New Project Trailer/RV

As promised:

Did a bit on the shower fittings during the week, the big moulding (molding) for the vanity unit had a couple of cracks at weak points, so we found some small U section channel at B&Q (Home depot in the US) and Sikaflexed that onto the edge of the moulding with some success.

With the toilet, shower tray and vanity unit in place, we had a mock-up to see how it would all come together. There were some fatigue cracks in the plastic shower tray that will need either a layer of EPDM over the whole floor of the tray, or we will need to try and find a replacement.

The people who made the parts went down the tubes in 2009, so not too hopeful of finding a new one.









Peter
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  #63  
Old 07-03-2011, 11:35:27 AM
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Default Re: New Project Trailer/RV

2 options open to us on the shower tray:

1) Repair the one we have.
2) There's one on fleabay, about 40 miles north of us.

We have some glassfibre embossed sheeting that would do the job, we could cut a piece out to fit in the base of the shower tray and seal it in with one of those wonder adhesives. The dimples that caused the cracking may have to be taken out, or we could possibly fill the base level with the top of the dimples and then put the new piece over the top. We could also do a double layer, one inside and one outside to give the base more strength.

The one on fleabay is purported to be in good nick, it's the wrong colour (color) for us but if it is the correct item then we are not too concerned. $100 or so.

Repair is cheaper, replacement is quicker.

Peter
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  #64  
Old 07-22-2011, 01:57:13 AM
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Default Re: New Project Trailer/RV

Bit more work done over the past week or so, we made up the false wall that the cassette toilet sits on and got that fitted into place, 120mm forward of the actual wall/divider.

We have a huge amount of GRP/ply and honeycomb left over, so it's just a case of picking a piece that's near enough in size and trimming it up. Two bits of 3/4" angle were used to fasten it to the outside wall on one side and the new kitchen side wall the other.








There is a 'hook plate' that the toilet sits onto, and there are three screws farther down which are going to be fun to get in. The whole assembly sits on a styrofoam padded base, and we have raised it up by 15mm so the outside cassette access door will clear the side rave extrusion.

There is a path under the shower tray edge, under the toilet left-hand side and through both walls for the hot and cold water hoses and anything else we want to run from front to back.

Pictures are a bit wishy-washy, didn't take them until after dark.

We have the covering extrusion for that big join in the divider, and are planning to fit that tomorrow evening. The screw heads will be this side of the wall!

Peter

Edit:

Got the extrusion fitted over the bulkhead gap, and reversed the screws so that the smooth heads are the bathroom side.

The H and corner extrusions arrived today, not particularly cheap but exactly what we need. The supplier has a minimum order charge so we just added more extrusion to make up the price.

Cut that tonight and had a trial fit of the panels, looks OK but we have a 1mm panel width difference between the channel and the panel, so will need to address that.

Went through the cassette toilet templates again, had to do a bit of patching up of old tears etc, but we have now made some sense out of it all and expect to cut the aperture on the weekend.

Edit 2:

Spoke to Thetford again about the new templates for the toilet, they say they will be here on the 27th. The set we have don't match the outer door, and I'm leery about cutting a big hole in the side without knowing it's going to be OK!
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  #65  
Old 07-26-2011, 03:57:39 PM
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Default Re: New Project Trailer/RV

More progress, although on many fronts so not a lot of visually interesting stuff.

Got the water heater ready for fitting, it's a balanced flue gas or 240V mains or both. Got to cut a hole in the side of the trailer, plus there is the water inlet and filter to go next door to it. We've decided to fit a new filter assembly as the old one was a bit drab and we don't want to pick anything nasty up

Bathroom walls are all in place and partially secured, just the last end wall to be modified, it needs a hole for access to the rear of the vanity unit so we can get at the back of the taps and switches etc.

Cut out the bathroom door aperture tonight, and took that panel's width down by 1/4" to make the corner square up properly. Looks OK, we've got to sort out the catches for the door as the width of the wall is less than the donor caravan, but it fits OK and looks good.

Rita is going to rub the wood down tomorrow and give it a coat or two of varnish.







The water hoses have been sorted out and they have to be laid in place before we fit the shower tray and vanity unit. There is room to pull them through, but I wanted to use P-clips to hold them in place. Also got to run a gas pipe to the water heater and 12V supply/control cable for that as well.

Peter
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  #66  
Old 07-27-2011, 09:42:42 AM
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Default Re: New Project Trailer/RV

New water inlet and filter arrived this afternoon, so the jigsaw is going to get some use tonight

Talking with the gas inspection guy about getting the LPG inspected and certified after we have finished fitting it out. Costs about $50.00 for the guy to come round and have a look, check fittings and pressure and issue a cert. Good money well spent.

While this is all going on, we are also making new axles for the Ruston trolley, eventually the 6-wheel ex-military trolley will be back on ebay and we should be about 1/4 ton lighter.

Peter
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  #67  
Old 07-27-2011, 04:49:38 PM
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Default Re: New Project Trailer/RV

Took the jigsaw to the body today and after a lot of tutting and lip-biting, cut the hole for the water boiler. It actually fitted first time, no hassles and nothing in the way.

Suitably emboldened I did the same for the water inlet and filter, but had to locate that under the vanity unit and out of sight. We will be fitting an inspection cover over a largish hole in the rear panel of the bathroom so we can get at these things and the taps etc from behind.









Hoses next, then the gas pipe to feed the boiler and the mains feed cable for the sockets and the heater in the living area.

The water boiler is gas and mains, and also has a largish polystyrene insulating outer sheath, which is in 3 pieces at present.

Then we can fit the shower etc in place and seal it in.

Peter
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Old 07-29-2011, 04:19:51 PM
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Default Re: New Project Trailer/RV

Laid in the 240V AC feed to the water heater and the sockets under the bed frames, fitted up the on/off switch for the water heater (switched fused non-socket outlet) and also cable tied the hoses that we put in last night. The water heater also has to have a gas feed fitted.

The water inlet and filter had the Sikaflex treatment, no more to do on that, we haven't sealed the water heater in yet until it has been tested.





Going to bring the fridge, cooker hob and separate oven down tomorrow and start to get that lot installed.

Still haven't had the template that was promised by Thetford.

Peter
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  #69  
Old 07-30-2011, 02:56:48 PM
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Default Re: New Project Trailer/RV

The Thetford templates turned up today, took a while to come but at least we were able to get hold of them.

After a bit of thought, we sat down outside the trailer and tried to work out how we were going to do the hole cutting for the cassette toilet. We used the loaned internal template to drill the two pilot holes, but once outside, the new sheets were found to have pilots that were centered vertically and horizontally, while the drilled holes were diagonally centered, top left to bottom right.

Fortunately, the Americans like to work in inches, and whole ones if possible, and after a bit of drawing on the side of the trailer with a set square and ruler, we established the centre of the old system. It was then fairly easily converted to the centre of the new templates and the outline of the cut-out drawn from the template.

Once hacked out with the jigsaw, which did very well on the rounded corners, we had the hole and it looked to be exactly right.



The door we had bought on ebay was offered up and holes marked on the GRP outer so we could just pop a small centre with a drill to get through the GRP skin.

Once we had run a decent bead of Sikaflex round the door outer, it was screwed into place, never to be removed again



When we came to the door infill, the template was too small, so we cut one out based on measurements taken from the door. That was sealed into place and we finished for the evening.



Just got to modify the toilet mounting wall to clear the door protusion on the inside, the trailer walls are much thinner than most caravans.

Peter
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Old 04-22-2012, 09:25:18 AM
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Default Re: New Project Trailer/RV

Lots of time gone by, and I haven't posted anything!

We didn't do much in the winter as it was too cold outside, but now the clocks have changed and we have lighter evenings, we are back outside working on the interior.

The kitchen units are now wired in and all the LPG hooked up:



The electronic ignitors for the cooker/oven are working, and the fridge operates on 12V and 240V OK.

The refillable LPG tank is being plumbed in, we have two filler points, one on each side as we cannot get a hose round the body, it's too big!



The regulator is up on the wall above one filler:



We have cut out and trimmed a large section of the bulkhead to get at the rear of the kitchen units:



More to follow on next post,

Peter
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  #71  
Old 04-22-2012, 09:26:05 AM
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Default Re: New Project Trailer/RV

Here are the other images:

Cut-out cover after trimming and fitting louvred panels:



Three-way tap manifold is in place and LPG hoses connected to the fridge, cooker hob, cooker oven and water heater:



We also fitted multiple floor vents to allow for cooling and combustion air in:






Peter
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  #72  
Old 04-23-2012, 06:01:03 AM
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Default Re: New Project Trailer/RV

Bit more of an update:

Because the fridge runs on LPG as well as 240V and 12V, we are going to fit an extraction fan in the compartment cover, just to draw out any fumes from the fridge.

Normally these are supplied with a chimney vent which goes to the outside of the trailer, but we cannot reach that far and it's a right-angle change of direction as well, so after looking at the volumes involved, a small computer cooling fan running at half-power will do the job.

Fumes from LPG are not toxic in normal conditions, but if the oxygen levels get low, then that changes to toxic fairly quickly.

I've got some HP computer fans that are 60mm square, and they will run half speed at 6-7 volts quite nicely, and more importantly they don't make much noise.

Peter
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Old 04-25-2012, 03:32:26 PM
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Default Re: New Project Trailer/RV

Odds and sods day today, but did manage to finish off a few items and get some pictures.

The extraction fan has run for 48 hours without problem, and I've reduced the voltage again by fitting a 47R resistor instead of the 33R that was on there. This has just taken the noise down to almost inaudible, but if you listen for it you can confirm that it is running:



The little cover over the other side blends in well:



The gas tank hoses are in place and clipped up where needed, the two braided hoses are for the filler side and the output from the regulator to the tap manifold.

Two 2" wide stainless straps are being made to hold the tank securely to the side of the trailer, with rubber foam underneath and between the tank and the side:





More on the next post.

Peter
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Old 04-25-2012, 03:32:48 PM
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Default Re: New Project Trailer/RV

Here are the rest of the images:




The painted panel twixt the oven and the hob has been put back on, and the shelf fitted above the splashback:





Still more to do, but the cooking side is almost done, just the shower etc to finish off.

Peter
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Old 04-26-2012, 03:30:33 PM
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Default Re: New Project Trailer/RV

Work continues, we have less than a month to go before Nuenen, and we want to have all the systems working this year!

Spent a few hours in the bathroom today, first of all getting the shower vanity unit set up in position, then I could get a drawing done of the shower tray that is to be made in 14g NS4 aluminium.



Once that was in place and cleaned up (it has been outside for a few weeks) I started to sort out the taps and plumbing.

We have pumped water through an external Aquaroll and submerged pump, all operated by microswitches on the taps. I might fit a relay in the circuit to save the microswitch contacts, but for now they are directly operating the pump.

The wiring is getting interesting, with feeds for this and that, and we are starting to use the extra ways that we have free in the fusebox.

Digging out all of the reclaimed shower parts, we had need of a new shower riser rail, £26.50 on ebay but found it a fair bit cheaper elsewhere. Shower curtain rail we have had to order new, Rita came up with a new set of shower curtains, so we are good to go.

Should get the shower tray drawing done for the metalbashers over the weekend.

Peter
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Old 04-26-2012, 10:33:21 PM
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Default Re: New Project Trailer/RV

Very Cool build you have here. Have you posted this somewhere else also? I coud swear I have red about this somewhere but can't figure out where. Thanks
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Old 04-27-2012, 03:26:40 AM
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Default Re: New Project Trailer/RV

Quote:
Originally Posted by ihredo4 View Post
Very Cool build you have here. Have you posted this somewhere else also? I coud swear I have red about this somewhere but can't figure out where. Thanks
It's on the UK Stationary Engine forum in greater detail.

http://www.stationary-engine.net/for...ad.php?t=15080

Peter
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Old 04-29-2012, 03:10:32 AM
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Default Re: New Project Trailer/RV

Amazing how the weather has turned!

This time last year we were complaining that it was too hot outside to work on the trailer, this April has been cold and wet, we are expecting local flooding in our area today.

Fortunately we are working inside the trailer, and with a small radiant heater it is quite comfortable.

Yesterday we got the roof lighting revised and put in new feeds from the LV fusebox for the water heater controller and the bathroom strip light.

Also fitted a door post light switch for the new lights that are going up over the kitchen, and ran a feed to the front end where we are going to have two small reading spotlights.

Lots of bits due from suppliers, but weekends are poor for deliveries.

All of the LV wiring is run in mini-conduit which is about 1" X 3/4" and has a snap-on top cover. Really easy to use and is self-adhesive for fixing.

Not sure what we are doing this morning, high winds and heavy rain outside

Peter


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Old 05-02-2012, 03:26:13 PM
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Default Re: New Project Trailer/RV

Lots done in the past few days, but nothing worthy of a picture. Largest jobs were fitting another switched AC outlet up in the kitchen, rewiring the fridge so that its 12V element only runs on the car electrics, not the trailer's own batteries. The 12S socket supplies additional feeds and functions which I don't think North American sockets do, and nowadays we have the 13pin DIN sockets on all new vehicles.

Huge pile of parcels and packets in the mail this morning, got bits to carry on with!
Spotlights to finish off the shelf at the front was first, bit of a fiddly job as there was a loop of spare wire inside the light base without a home and I couldn't get rid of it. Eventually took a single turn round the on/off switch body and all was good.



Got serious then and took out the front cupboard unit to sort out the bed slat guides. These keep the bed slats that run between the two side beds in place and straight. The original caravan bodywork had these included but they didn't transfer across to us.

More copper gas pipe and unions were in the parcels, a specialised nipple for the water heater turned up and the new shower curtain rail, which needs making up into what we need in the bathroom.

Cut the awning rail and got that screwed in place. Got to take it down tomorrow and seal behind it before finally fixing in place.

Hung the Caravanstore Xip bag up in place, just needs some end caps to stop the awning sliding out.



The awning can travel in its bag up on the side, there are cushion pads under the bag.

Fire blanket joined the extinguisher on the door, not a reflection on Rita's cooking!

Still lots to do, but the list is starting to thin out quite nicely now, almost there!

Peter
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Old 05-02-2012, 08:26:02 PM
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Default Re: New Project Trailer/RV

Peter, that's just outstanding workmanship!! If a person didn't know better ,they'de swear it was a factory built unit. Which leads me to my question, Where did you get the knowledge to tackle a job like this? Have you built trailers in the past? I can tell from your posts that you're very mechanically inclined, but that aside, where did you,how did you ever find the resouces to get all the material to tackle this fantastic trailer? I can't wait to see pictures of the finished job. Thanks for documenting and posting all the steps . Mark
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