On the Road at Last

A quick post here with more details and pictures to follow (since this has been a hectic summer). The wagon is finally roadworthy! The interior is far from finished but the structural stuff is done. We took it to Echoes in Time last week for its maiden voyage, following a road and stress test earlier. We had a really great time and had many visitors and many great discussions. I was quite surprised at the number of people who knew of other builds. 

Having the sun come up one morning and light the interior was a moment that made all the hard work worth it; that and my daughter's delight at sleeping in the lower cozy bunk-bed.

Towing was far easier than expected even in a fairly strong wind, with the total lack of aerodynamics not appearing to present much of a problem. I kept the speed at 65mph.

A Handy Cheap Forge

The marine rail and latch for the stove were fashioned from 1/4th inch mild steel using this simple tin-can forge. I was introduced to this handy tool by Kiko Denzer at Echoes last summer. All that's required is a large tin can, a pair of holes, some kaowool, a turbo torch, and some firebricks. The forge is very useful for making small pieces of hardware, and unlike the rivet forge, is very quick to set up and very cheap to run.

Stove is Installed

This has been a fairly major project for the last month. The stove itself is a customized version of the Scout made by cylinder stoves. The owner was kind enough to sell me an un-assembled stove as well as fabricate a shortened barrel, allowing me to reduce the stove from its original 16" length to 12". I took the stove to a local welder for assembly, and I welded the legs and hinges myself. I modified the door hinge slightly to accommodate a fiberglass door gasket, and added the marine rail for aesthetics.

The heat shield is made from 1/4" tile backer to which has been glued 24 gauge steel, although I have used 16 gauge steel for the left side and base. The base is attached to a frame of 1"x1" steel tubing, and is 2" off the floor. The front edge of the base has a lip to help catch any embers that may fall.

I used stove gasket cement to bond the steel to the mineral tile backer. The shield is attached using carriage bolts and spacers to leave a 1" space between the shield and sides of the wagon. In the lower right of the right hand heat shield is a 5" x 2.5" combustion air vent.

When I am able to move the wagon out of the shop I will fire the stove up and use a laser/infra-red thermometer to check the effectiveness of the heat shield. I only intend to use the stove lightly to take the chill off the morning air, but would still like it to be far more safer than it needs to be.

Porch is Done

The porch and steps are almost finished, and I've installed the fascia trim. Its starting to look like a wagon now.


Following some questions posted earlier by Keith, below is a pic of the compass jig that I used to make the curved pieces. The jig has preset holes at the far left, and is attached to the bench with 1/4 carriage bolt through a bronze bushing. There is an adjustable plate near the router end that allows for fine tuning. As I mentioned already, the key here is to use a non-plunging router, as this will give a nice clean cut using four passes.

As requested, here is a larger image of the interior.

Progress on the Interior

The master bedroom is coming along. The bed platform is almost complete, as is the storage below. Borrowing heavily from George's work (see the link above) I've installed eastern aromatic cedar around the bed area and along the sides. I've also put fiberglass insulation in, which was covered with plastic sheeting prior to being enclosed with cedar. The bed platform houses a pull-out table made from scrap wood and an old mahogany table leg I found at an antique shop. The leg folds up under the table for storage.

The bay window is in, along with some nice brass English hardware. This window was quite difficult to make, there being lots of angles and mortise joints. I followed the constructions method outlined in this great article from Woodworkers Journal (the same method I used for the door). The router bits were expensive, but will worth the investment. I will eventually install plexiglass, and make a wood cover for traveling. This project took me about two weeks to complete, and still has to be varnished and roofed.