Tuesday, November 20, 2012

Door is coming along nicely

I've been working on the door for a couple of weeks and its almost ready to sand and varnish. Its made from 5/4 fir, reclaimed spruce, and and an old closet shelf that I found at a yard sale for $2.00. I used this latter piece for the raised panels. I used spruce for the window--it is much more friendlier on the router that fir, which tends to splinter. I plan to put plexi-glass in the window. The door measures 28 by 72 inches.


  1. Wow. It's going to be too awesome. You'll gentrify the neighborhood and I'll be the ghetto.

  2. Oh, I don't know about that--but leaving the banjo at home should help.

    1. For those of us blessed enough to be born in the Ozarks, we are issued a banjo at our coming-of-age. We may be poor and unemployable, but it's hard to be sad with a banjo. Besides we usually find a few real musicians to hang out with. We make them feel superior!

    2. Point taken, but be warned: the banjo is a gateway instrument. Pretty soon you'll be on the pipes. It's already happened to one friend of mine.

    3. Och aye! If only I could.

  3. Hi Mick, I'm really looking forward to seeing this all finished, It's going to look stunning, Very well done.

    Have you any idea on weight yet? I'm going to be limited to 750kg's on my build so just wanted to get a rough idea is all.

    I live 30 minutes from Stoford btw ;-)


  4. Keith,

    Thanks! The weight issue this is a constant concern. I've used lightweight materials as much as possible (cedar and spruce) though still don't know the weight yet. As a proxy though,I can still easily lift the wagon by the tongue. My trailer is rated for 1300 kg and my goal is to come in at around 60% of that.

    You hail from Taunton right? I actually grew up in Barwick, not far from Yeovil. I was there a couple weeks back visiting my mom, and bless her, she didn't mind one bit visiting numerous ironmongers in search of brass hardware (you can't get good quality brassware in the States).


  5. Yea I'm from Taunton, and yep I know Barwick too, small world isn't it :-)

    I've been doing some research on materials lately, WR Cedar comes in on average at 390kg,m3 and Spruce comes in at around 4-500kg/m3 (obviously depending on moisture content)Probably not going to be putting the log burner etc in mine though, can't trust the kids with that. Small oil filled rad on hook up will be fine. Anyway I'm really hoping to come in under 500kg's to give me some weight for the camping gear. I'll keep an eye out for any weight updates (and minus a rough amount for your cupboards and burners etc)

    Can i ask what you meant by "joining sections cut with a router/compass jig" when referring to the ribs and possibly some pics? I think i know what you mean, just wanted to check.

    looking forward to the next instalment


  6. Keith,

    Small world indeed.

    The router/compass jig is just a simply plywood device. To minimize wobble I used brass bushings at the pivot end, and have found that a non-plunging type router produces superior results. I used 8" wide cvg fir boards, and made each of the four ribs in four segments. As you no-doubt know, with this material you really have to pay attention to the cutting direction, and make multiple passes, to avoid tear-out. I chose fir, though, for its superior strength. I attached each segment with a biscuit (plate) joiner and screws, using the back wall as a template to ensure uniformity. It took several weeks to complete, but was well worth it--at least aesthetically (I have no idea how it will all hold up on the road test).

    Good luck if you should choose to go this route.

    Do you have any postings of your project?

  7. No postings yet Mick, all research so far (you remember those days lol) mainly Paleotool's webpage, and a few others. Emailed Daphne who was very helpful. First of all I wanted to make a bowtop, then read somewhere that it was like towing a parachute, then i started looking into Schäferwagen's (german sheperds wagon's) http://www.schaeferwagen.de/schaeferwagen.html , then I came across your thread and the resin canvas idea. Brilliant I thought, back to the original plan.

    I've built a few teardrop trailers so far and they are okay for the children to sleep in, some adults seem perfectly okay sleeping in them, but a bit claustrophobic for me.

    Once i saw your build however, that was me hooked, I'm going to strip my teardrop down (had some ply de-lamination problems with Chinese ply)and build one of these.

    A friend of mine want's one of these building as well now, so I guess I'm going to have to look at the UK regs more closely as he wants a woodburner in his. I've also got to get a cutting list together, one to price it all up and two to see where I'll be with the weight.

    Thanks for the explanation on the ribs, understood perfectly.



  8. Hey, thanks for the links. I really like that stove in the German wagon. Daphne's stuff is good too--I really love their interior work.