Teardrop Trailer Build

A  couple of years ago, I decided I wanted to try to build a teardrop camper. I read a few forums, searched for plans and took notes of all the best ideas. But I never really took the first step and purchased anything. Well, this last fall, I finally did. I bought a 5x8 folding trailer kit from Red Trailiers and started with that.

All the fixtures, trim and plans came from Vintage Technologies.

Here's what I hope mine looks like when it's finished. 

Wineberry Teardrop

You can click on any picture to enlarge it. 

This is the kit after I unpacked it from the several boxes that it came in. I was surprised that they shipped it UPS, as was the UPS delivery guy... They probably put it in so many boxes to keep under the 50lb weight limit. Every piece is nicely powder-coated.

And this is what it looks like assembled. I'm not using the kits fenders or tail lights, and I swapped out the stock wheels for some ones mounted on some very nice aluminum wheels. I also didn't use any of the folding joints, as this will never fold. So it is all bolted down tight, and every nut is a nylock. This trailer should last a long time.

Next I built the floor. Two pieces of 3/4" plywood joined in the center. This is actually the underside, and will be insulated, then covered with aluminum to prevent damage from the road.

Here I am cutting out a template, using a drawing I purchased from Vintage Technologies.I'm going to be getting most of the accessories from them, as well as picking their brains for ideas and techniques.

The finished template. I will use this to draw out the lines to cut on the actual sides. 

And here is an idea of what the trailer will look like. All Yvette can say is how 'cute' it is... 

I'm hoping it will turn out anywhere near what I'm imagining... 

Here I am gluing down 1/2" foil backed styrofoam. 

All done.

I decided to cover the bottom with masonite instead of aluminum due to the cost factor.... 

The bottom of the floor after being undercoated. 

The masonite plus the undercoating was actually not that much less than a sheet of 5x8 aluminum, plus it would have been a lot less work. I think I'll go that route next time.

I rigged a stand to hold the two sides together so I could 

sand the edges flush with each other.

Two coats of polyurethane. It looks a lot better in person.

The finished floor.

  Added the sides.

It is finally starting to take shape!!

Installing the Headliner. 

This is actually the second headliner I attempted to install. The first one was some pre-finished masonite that looked like 1" slats. Painted white it would have looked very rustic. The masonite proved to be to inflexible however, it would not stay glued to the spars and I didn't want screws or nails to show. Looking thru Lowes I found this Fiberglass Reinforced Plastic (FRP) that is used to line showers or kitchens. It has a pebbled surface that is glossy and should be easy to clean plus it is extremely flexible.  

I got the galley pieces cut and put into place for a test fit. Here's a pic of how the interior will look. I still need to cut the openings for the cupboards.

And a pic of how the galley will look Now I need to disassemble the galley to cut the cupboard holes and stain everything... 

The Galley re-assembled and stained.

Got the 110 wiring and the battery feed pulled. 

Closeup of the Power Control Center, GFI outlet and 12v outlet 

The backside of the Power Center

The initial fitting of the siding.

Got the first door installed!!

Installed the siding and the second door as well. No picture, it looks just like this one... 

Starting the insulation

Insulation almost finished

I routed down the sides, and I've glued down the roof.

I'll let it sit like this overnight. 

Front view

I installed the cabinet doors while the glue was drying. 

The next day I started the trim, it went on much easier than I thought. 

Looking good! 

Oh, the trailer is really starting to come together... 

This is the corner above the galley door. Remember, you can click on any pic to enlarge it. 

Close up of the corner with the vinyl insert installed.

Things were going too well... once I got all the trim on, I decided to finish out the shore power outlet. The bad thing was when I connected the extension cord... 

The GFI circuit in the garage popped. 

I unplugged the extension cord and verified that I had a short somewhere in the main line. 

Damn. 

Well, I 'had' a headliner... I ripped out the rear section first, as it was easiest to get a grip on. Unfortunately there was no way to remove it, except in pieces. At least I know it was fastened up there well.

And there is the culprit. 

 I found one spar where I had missed a screw guard. And of course, there was a screw, and the cause of my short. I chiseled out the cord and inspected it, no damage. The screw threads had barely cut the insulation, just enough to make contact. So I taped up the line, cut out the screw, and repaired the spar.

Tomorrow I replace the headliner... 

The replacement headliner is in place.

The first half of the masonite goes on the galley door.

The aluminum skin being glued down, held in place by ratchet straps. 

The fenders and the toolbox installed. 

Galley light temporarily installed. 

Side view of the extended counters.

Another view of the extended counter.

Counters in the closed position.

Counters in the open position. 

Closeup of the corner showing the Q channel and D channel weather stripping. 

Galley headliner being installed. 

 Completed Trailer

Open Galley