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Thread: Escape Pod

  1. #61
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    Prop stands needed to be fitted – I had been putting this off as it meant that I needed to get underneath again to finish the welding – which meant taking it all apart again and turning it on its side but it had to be done - this did give me the opportunity to put some stain/sealer/varnish on the bulkheads and rought off all the sharp edges –oh and find camera that er got lost in the mess again so er sorry no picks of the myriad thinks that needed doing and the bits and pieces that turned up last week but I will catch up as stuff is fitted.



    tacked into position prior to welding proper



    pile of bits – running out of space big time



    Electrical bit and pieces need mounting/hiding/connecting



    Panel marked and hole cutting started



    I can finally put the bits together now that I have finished all the chassis welding, sealing, fitting mudguards etc. frame glued, screwed and don’t know the term ‘biscuit jointed?’ and first internal panel set in place (glue drying) and lining of floor insulation started


  2. #62
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    I haven’t been lazy and idle, Er well I have buts that’s because the family made me go on a family holiday (a cruel and un-natural punishment I am sure I don’t deserve? Teenage daughters go figure?)

    so happily back in the garage and fitted the partitions and started the wiring



    some of the panels didn’t quite align properly – they were pulled out of position a bit when bolted to frame and no amount of wiggling could get then just right so had to be planed/sanded (and will be resealed)

    Er..did I say I hate electrickery and wires – switches and distribution for 12 and 240v, power supply and conversion both ways RCD/fuses and meters, and the feed from the S type towing plug



    plugs for entertainment system (Er TV)



    Controls and stuff



    Need some more panels now so I can mount and fix other stuff, and route wires for lights and things – one at a time building out slowly


  3. #63

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    Loving this - should be snug as a bug with all that insulation.

  4. #64
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    A little bit more visible progress – loads of time spent doing fiddly little jobs that take loads of time but nothing to show for the effort; like testing the water system (and taking it apart again and remaking all the connections with silicon – and there was me having faith in the supplied rubber seals - fool) and making a wiring loom for the driving lights only to have to cut the side lights out and return them as they didn’t work when powered up.
    So internals coming along – panelling, bed and some storage and shelf's now in, will it be a bit dark? (Will see with the lights, roof vent and portholes are fitted) might need an coloured feature wall thing to bounce some light around a bit.

    note green light on solar controller - all 12v system (that is so far connected) all working now.



    bed in the folded up in ‘back of seat’ (and access to storage) position – just need to make a seat for it (Er… and do some upholstery )



    I have bitten the bullet and ordered the external cladding – after extensive research I have decided that I can’t justify the potential cost of what I wanted – an engineered (impregnated) softwood, or a decent hardwood cladding the best price I could get was £8+ per meter and I need about 190 liner meters (with wastage) at 95mm wide, 7 mm thick T&G and that would have cost £1500 – yes ridiculous! So plan B, pine cladding, tub of oak stain and tin of yacht varnish (and a lot of brushwork)- still cost £145, and that is ridiculous as well! why is wood so expensive - I thought it grew on trees?

  5. #65
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    some progress

    Internal shelve,s, cubbies and panels (except ceiling) finished (12v TV in)– I will use old rubber mats to line the rest of the floor/storage (and to soften some hard edges)



    did a diagram of the electrics for the driving lights – thought it would help, not that sure now



    and wired some more lights into the loom



    made the frames for the two doors and glued (will pin and glue in a panel when dry) - glue setting with frames in position so they end up the right shape (Er.. they are not exactly square – nearly but not quite). yes here I am presented with a problem; I don’t have enough room if/when i fit the doors to open them?


  6. #66
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    Time for some more insulation



    I could cut and fit insulation all day, it is such a satisfying material to work with – its light, it cuts easily -it is just a joy





    Er.. it was a warm afternoon, had to try the bed out for size and check the level thought it best to do that er lying down – bed works



    Started cutting the cladding



    managed to do 19 odd lengths when saw motor bearing gave out, cooling fan met casing and then it flung bits of it’s self all over the garage (frightened the life out of me I just ducked knowing that the saw blade was obviously ricochet about looking for somewhere soft to come to rest). I’m sulking now 70 odd bit to cut by hand or buy another saw Hmm..…and the roof/ceiling panels still need to be cut - moan grumble…

  7. #67

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    Now if ever there was a need to justify buying more power tools, this has got to be it!!!

  8. #68
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    thank you tankosi, Er justifying buying a tool not a problem - deciding on a purchase of something that I will have to live with for years much more difficult, same again or bigger/better - sometimes only a table saw will do but most of the time its just a heavy lump that is always in the way, anyway emergency spare (firewood) chop saw deployed.



    some cladding cut and stained (enough to be getting on with)




    I will stain again and then varnish when fitted,

    can finish preparing the cladding as these 25 length are going back to the supplier as they are cracked, split have holes where knots have fallen out and are not straight and /or are warped etc out of the 90 supplied that is not a very good hit rate.



    more delays..Ho hum..

  9. #69

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    25/90 is not a good failure rate..........I've bought a few bundles from a supplier (starting with a B and ending with a Q) with similar issues. I've now started sorting out packs myself before I go to the till!!!!

  10. #70

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    Agree Tankosi, I'been doing a few woodwork projects and getting decent wood is not easy, I knew to check for bowing and would quite often go through several and then open a few of the four packs to find a decent one and noticed you have to check for twisting as well plus dead knots.

    Never buy 'to be delivered' and always check your wood.

  11. #71
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    Not having a good day, first off our favourite DIY store delivered (finally, ordered over 2 weeks ago, apparently they had run out of 5mm exterior ply – go figure, no body is ever going to want any of that?) my final two panels – just look at the state of them – one is so bent it stands on its own edge, the other is not much better – ive put customer service on speed dial - they are going back,



    then this useless piece of junk broke



    The arbour just fell off, and er..; no I was not abusing it. The casting had been drilled off centre and there was almost no material at one edge,

    internal bit..



    external bit


    trying to find receipt / guarantee now, I bet its 13 months old (ive only used it twice!)
    I would really like to have shown some progress from another long day in the garage but what with lack of materials, tools committing hari-kari, and the rain (not enough room inside left to work, cant put pod on drive yet as its far from watertight) sort of stopped play today, hopefully better progress tomorrow.

  12. #72

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    But you must be excited??? Just think of the fun you're going to have, stood at the customer services counter on a Sunday morning......some of us can only dream of such pleasures!!!
    Good luck!


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  13. #73
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    much as I enjoy a good rant at an idiot as much as the next man, I have been credited to the tune of 20 good English pounds (for the inconvenience) and have been the beneficiary of a personal delivery of decent ply sheets as a result of a well crafted expertly aimed personal email ( these people should'nt glorify themselves on linkedin) - still waiting for the replacement cladding (apparently they have run out of that as well). found the sander thing receipt - deep joy, 11 month old.. returned to manufacturer for replacement (I will wait with baited breath....)

    it stopped raining so I started on the kitchen pull-out.



    templates in hardboard and cardboard being copied in ply (fingers crossed, curve measured from an imaginary point in space)



    worktop, supports and draw/pull out bits



    parts (some) assembled (glue drying) just about ready to see if the not quite square door will fit into not quite square hole..



    well it fits (just) - this is looking down (in plan), hinge for kitchen pull out (when fitted) will be right hand side corner (bottom right in pic but outside).
    in this the closed position the pull-out will cover the fridge and rest/press against (as yet not made/fitted) storage to stop then both opening (and throwing stuff around) when driving (well that's the plan) - the sink section (bit with the hole) folds up against the door and the sink (stainless cooks mixing bowl) protrudes into the compartment on the left when stowed


  14. #74
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    more bits - the repurposing of an old chair




    fitted in stowed position



    seat deployed (E.. I do have a nice cushion somewhere)



    Er.. facilities configuration



    first ceiling panel fitted (which is why its so dark in the pictures) - think I will paint this white or light blue - bit scary cave at the mo.



    3 position swivel table fitted

    1st position, stowed - surface sufficient for cup of tea



    2nd position - dining, seating on bed



    3rd - working? laptop - seating using pull down seat



    next job I think (there are a lot of possible contenders) is to work on the dedicated storage for the things I like to always take with me - every thing to have a space and every space to have a thing...another of my old Nans sayings
    camping chair (and other long things, but under 1.4m) will go above the kitchen, through the hole I left in the kitchen bulkhead (top right)



    camping table will go under the bed on the floor (will slide in and out)

    BBQ/fire stand/tray, petrol lantern (and flue store -gas and petrol), tools (saw, knife, axe, pliers, tape, hammer - you know the sort of stuff), canopy (that I haven't made yet) all needs a dedicated home, I am sure there is other stuff... - I need to do all this before I can think about cladding or more electrics as I don't want to put wires in the way and may need to put more fixings through the inner lining - doing this is proving to be a bit of a puzzle, I know generally where I want to get too but the order of doing things to get there is perplexing?

  15. #75
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    started the cladding, I am nailing (nail gun and staples) each length to the frame top and bottom and filling in behind as I go with expanding foam - should fill in all the gaps, act as a glue, a waterproof barrier, stop vibration and sort of hold it all together(well I hope so)



    one end done.


  16. #76
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    Ingenious to say the least. I may be inspired myself.

    But then I see you are an engineer. I don't think I'll manage!
    Last edited by David Perry; 28th-August-2016 at 12:27 PM.
    http://www.davidwperry.blogspot.co.uk/

  17. #77
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    thank you David, yes slightly frustrated engineer, they took the tools off me years ago and I have to let kids do the designing now as well - reduced now to various forms of oversight ; but they can't control what you can do in the sovereign territory of your own garage, Er..apart from the noise maybe?

    clad another side



    and started to dry assemble the bottom portion of the stable door



    I know it looks sunny, but 2 mins after this rain stopped play - hopefully nice weather and more progress tomorrow

  18. #78
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    wheel arch cutting jig mark 1 -&nbsp; I new this would be difficult<br><br><img alt="" src="http://i300.photobucket.com/albums/nn23/stephen_palmer2/Escape%20Pod/P8290930_zps0doy83qf.jpg" border="0"><br>&nbsp;<br>wheel arch cutting jig mark 2<br><br><img alt="" src="http://i300.photobucket.com/albums/nn23/stephen_palmer2/Escape%20Pod/P8290931_zpskx30oqik.jpg" border="0"><br><br>quite pleased with result - missed the tyre and the mud guard<br><br><img alt="" src="http://i300.photobucket.com/albums/nn23/stephen_palmer2/Escape%20Pod/P8290932_zps4pzakuog.jpg" border="0"><br><br>holes for water and electrics<br><br><br><br><br><br><br><br>


    Er..server busy? will try again later?

  19. #79
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    if the server is ready I will try again...

    wheel arch cutting jig mark 1



    wheel arch cutting jig mark 2



    quite pleased with result - missed the tyre and the mud guard (the feathery edge cleaned up with a sanding pad)



    just have to repeat that on the other side...

    holes for power and water (power in the upper one so I don't pour water over the electrics)



    2nd ceiling panel ready to install - I went for midsummer midday sky blue (might distract from the inevitable rain?)



    its looking ok inside, lights fitted (and working)



    driving lights fitted



    still lots to do..
    steve

  20. #80
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    I have put the driving lights wiring into an old bit of hose



    I hope will afford the wires a bit of protection



    Where I have fixed shelves and dividers internally through the inner skin I have reinforced the fasteners with some big washers (Er..dont want them to pull through)



    fitted both doors



    stable door (inside face is still a design in development – trying to decide on the merits(and safety) of mounting a small gas fire into the lower door (vented to the outside)– toasty or death trap?)



    Kitchen door



    folded



    stowed (looking down - ceiling still to fit)



    it fits in under and against the storage, long thin (white - because it is deep and will be dark) pocket is for camping chair, and when the door is fully folded out (can’t do that in the garage not enough space) the fridge becomes accessible



    I have been thinking about how to waterproof / seal the hinges for the two doors






    so I have cut up an innertube and intend to silicon this across the gap and under the adjacent cladding



    will have to se how that goes?

  21. #81
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    Its looking smaller every time I look but you seem to have thought about everything. If you use it in winter will you be able to 'operate' the kitchen from inside?
    http://www.davidwperry.blogspot.co.uk/

  22. #82
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    cheers David, thought I don't think I am close to having thought of everything, i did think about accessing the kitchen from inside and then when I couldn't work out how to do it decided it wasn't necessary - I intend to make a small clip on canopy that fits between the open doors to provide some quick cover and a larger fly (that can be left up with the doors closed) for more permanent setup.

    finished cladding the doors




    and have cut another wheel arch



  23. #83
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    Finished cladding the back



    fitted the second ceiling panel and finished most of the wiring (just the vent fan and external mains and TV signal plugs to do)



    internal space passed the Tea break test.


  24. #84
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    Er.. if anyone thought that my idea to seal the door hinges using an inner tube was a good idea - it wasent. I still think it will work but it is proving very difficult to implement.

    rubber just don't stay in place while it is being stuck






    hopefully tomorrow when I take the supports away it will stay there long enough to fit and pin/glue the cladding on top

  25. #85

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    Could you not staple gun it in place then overlay with the wood trim and a bit of sealant

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  26. #86

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    I believe the inner tube is used to cover hinges with tear drop campers, I think one way was to use an aluminium bar to clamp it down over the original hinge. Is that what you are hoping to do with the cladding?

  27. #87
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    Thanks Kneiling I didn't want to pin in position cause staples = holes, but in the end that's what I had to do. and yes steve clamping with the cladding but also glue so I have more confidence that it will seal.



    I pulled the staples out before fitting the cladding – did the kitchen door first (it was the easier, not having the split) – so I have inner tube glued to frame and stretched across the hinge, clamped under pieces of cladding (that are themselves glued to the outside of the inner tube) and then it was all stapled and some more expanding foam as used to tie it all together with the rest of the cladding – and so far the door still opens so I have managed to do it without gluing the hinge





    this is the door hinge, the last but 2 pieces of cladding (I will be glad when its finished and I can start sanding and varnishing - I need it out the garage so it needs to be waterproof) the unmoving bit – just the two stable door bits to hold the rubber the other side to go (got to leave it till tomorrow to dry)



    ceiling insulation in almost ready for the lid


  28. #88
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    Finished the last piece of cladding (yes it needs some tidying, Er. and trimming so doors open at least 90 deg, currently slight interference that will be sorted with a couple of chamfers)



    some corner pieces fitted to the front edge and now ready for sanding and varnish (and a small bit of fettling)



    holes cut for portholes, nice layers; internal skin, insulation board, expanding foam and external cladding – only a few voids needed filling (will trim later)



    small drama - FIRE , I found the garage lights in a skip about 7 years ago and one just exploded - I have 12 more wired in should I be worried (someone obviously threw them out originally, maybe I have just found out why?)


  29. #89
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    On heating, have you considered a Webasto or an Eberspacher?
    "Oh, Eeyore, you are wet!" said Piglet, feeling him.Eeyore shook himself, and asked somebody to explain to Piglet what happened when you had been inside a river for quite a long time.

  30. #90
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    cheers Tyro, I have some experience of these diesel fired heaters from friends boats, I did consider something like that initially but for number of reason (cost, storage / smell of diesel, even the smallest units would heat something with 5 times my volume) decided against that sort of thing - they are also quite noisy in a small space, require fibre insulation (they get extreamly hot) and would require another hole for the exhaust.

    I went round all the cladding and found a couple of placed that sounded hollow, so I drilled a little hole and injected some more expanding foam (dont want anything vibrating it might fall off)



    when I came back to check it - it had done this.



    wont do any harm, but obviously there were more voids than I imagined

  31. #91
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    Looking good Steve, this is going to be a luxurious abode

  32. #92
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    Cheers Kmac - design continues to evolve, looking to generate and channel an ambience of 'travelling gentleman's private members mobile lounge (membership 1, lists closed) authorised for the consumption of beer wine sprits cider and tea on and off the premises anywhere I dam please'...

    Final roof panels being cut



    one fitted and the last one going on (after sealing / staining)



    screwed down onto a bed of silicon frame sealer with some expanding foam to bond it to the insulation (should stiffen it up and stop it vibrating/flexing too much) – I have at least established that it will take some weight (mine) as I had to get up there to put screws in.



    roof vent hole marked – I drilled through from the inside for alignment – slot started with plunge saw ready for jig saw







    box is now complete and all penetration are prepared ready for the fittings (water, electricity, portholes, & roof vent) later – now ready for some coats of varnish – Er to avoid literally having to watch paint dry, I will spare you any pictures of that progress – fingers crosses for some warm weather so the varnish can dry and be sanded properly between coats or this will take ages.

  33. #93
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    good weather for varnishing so got two coats on , all lights, and reflectors fitted - will probably do another coat of varnish on front and roof (as there is still some left in the can)





    first porthole in.


  34. #94
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    final two portholes, electric and water inlets fitted



    some more work on the internals



    solar panel and roof vent/fan fitted, wired and working (fan is pretty noisy, panel was sending 17.2 v to the management panel and that was giving 13.2 v to the battery and running the fridge, it was in the shade). I should now have a waterproof box (if all the sealing worked) but will leave it in the garage to give it a bit more time to dry prior to its first wetting.

    I think I will make some little wind deflectors to go in from of both vent and panel and I need to make some brackets to support the canoe above both.




    tap plumed in, kitchen varnished (cutting board conveniently provided by the need for a hole for the sink, fits in the sink = nice (will give it a sand and then apply some oil)



    now to concentrate on finishing the inside.

  35. #95
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    Fiddly bits – draws for stove and pans going in



    battery wedged in – I have some spare space here beside the battery but don’t know what to store here, something that I don’t / won’t need often (as it’s not the most accessible areas) may be some tools – suggestions welcome, it may be needed for a second battery – will have to see how things work out – incidentally, now it is all connected up the solar panel works in the garage charging the battery (when the lights are on)it wasn’t giving the 17+ volts outside but was supplying a respectable 14v



    cleaning, final fitting and putting the inside back together







    I made some shutters for the portholes



    it got its first wetting today (it pigging rained while I was walking the dog) and all seems well (I am more worried about motorways in the driving rain, and I expect I will have to invest in some stick-on sealing strip type things for the doors, but so far so good)



    when I have finished fitting the lock (there must be an easier way to do this rather than with chisels and drill?)



    it can go outside permanently (I may make a cover out of an old tarp) and then I can put the canoe on top and make some brackets / rack / support / clamp things, the end is in sight (albeit some way off)

    the box is just about finished now so err..some sewing - internal furnishing, floor lining and canopy next. I started putting some stuff in; chair fits in its space (nicely) the fire basket/BBQ goes in its space (err.. not so nicely, but I can live with it) - few more bits required - spice / utensils rack, fixings for stoves, bits and pieces...(err.. I brought an optic for er.. obvious reasons but for the moment it is lost in the mess



    still need to sort out some heating…

  36. #96

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    You're making huge progress.......with the amount of insulation you've got, will you need heating? I reckon you'll be pretty snug in there anyway.....


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  37. #97
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    For the door seals couldn't you use some of the strips they use on car doors and boots? These are pretty flexible and are normally hollow on one side so they always fit any gap smaller than their uncompressed width/size?
    http://www.davidwperry.blogspot.co.uk/

  38. #98

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    I am planning a tear drop camper or similar I plan to use 240v but I was looking at tube heaters
    http://www.screwfix.com/p/dimplex-ec...ater-40w/3951f
    these are low output about 40-120w and due to the small volume of the space and body heat I thought I would use one of these to keep out the chill and dampness.

  39. #99
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    thanks steve, tube heater is a good idea and I have been considered one (I use one under my koi filters to stop it all freezing) but requires 240 volts - could run the generator (noisy) or the inverter (not that efficient) but on the plus side small, efficient, sealed/waterproof, silent, could be left on overnight/self regulating & nice to warm toes on so it might just be the best on grid option.

    off grid may just have to be the traditional hot water bottle and err.. candles

    cheers dave, I have been looking at strips - there are just so many shapes, materials, and options - I am still looking

  40. #100
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    Finished fitting the lock (should have thought about this some time ago and made the slots using the mortises machine when the frame was in pieces – would have been a lot easier) - one lock; top door releases bottom door to pull bolt for kitchen door (best keep spare key in car)



    time to try the canoe on top - temporary supports.





    I can still open the back of the car (enough to get in / let dog out) and it overhangs the back by less than a meter.



    I put some studding across the top and it measures 2 meters 8 centimetres and 3 millimetres between it and the ground --so under the original 2.1m target (just) - don't know what photobucket did to the picture?



    after some measuring and shifting about permanent Front canoe clamp/bracket/support – slots underneath for straps and slots/stops to stop canoe sliding about (will stick on some rubber/plastic strips when both are varnished)



    rear bracket



    little tube heater turned up and got fitted in foot well - it says do not cover but if I take the sticker off surely I can put a rack above it for hanging stuff to dry?



    Mattress (and free pillow) turned up and that fitted very nicely in its space – and very comfy it is too



    refitted the original plate – in a more prominent position , the other original plate is on the axel but is a bugger to see.



    did some more work on the facilities, so it all locks in position





    and with a nice memory foam cushion (seat configuration)




    err nearly finished?..only a couple of dozen more things to do; kitchen door support, utensil storage, canopy, canopy fixings, flooring, weather sealing for doors, midge screen for door, (and roof vent – the one that came with it would present little difficulty for our wee Scottish buzzing friends), err general tidying - the list goes on though in truth I expect this will continue be a work in progress / evolving for some time .

  41. #101
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    Hi Steve you were asking where the blog is for my 'snoozebox' , I did a blog but it did not start out as a trailer idea, it started out as a camping trailer with a view to carrying some chuck boxes or wanigans as I really enjoy outdoor cooking.

    in fact the original post was whether or not I need to strengthen my car suspension to carry all my camping kit. Anyway the link is below .......

    I think your trailer is amazing, now........when I made mine I had a few sleepless nights whilst I figured out how I did things, I wonder if it has had the same effect on you? Given the complexity of your project, I would imagine it has. But it is looking good to go. Hopefully we can compare on some marauder's meet somewhere at some time. You are doing really well!!

    Anyway in case you missed the link to mine here it is http://www.songofthepaddle.co.uk/for...car-suspension

    Good luck with finishing it!!

    Dave

  42. #102
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    cheers Dave I did find your blog - I had thought it was about car maintenance? sorry. I like the dedicated boxes.

    I have my garage back but have to get on with the next job on the list (wardrobes-not my choice)

    pod is now on drive (this is apparently ridiculous (not my words) so one of the other trailers has to go? I will put an add in the correct section (but sneaky preview).



    canoe trailer (big capacity, has carries 2 Canadians (or 1 Canadian & 2 kayaks 4 bikes huge amount of camping gear. built on a 1750kg caravan braked chassis - new electrics, bearings, tyres and sealed underneath when I built it 8 or so years ago comes with lockable box - offers? happy to do some mods to the steel work to fit specific requirements (as long as its not too complicated) I will put some measurements in a proper advert



    as the box is (just about/sort of) finished I have been sewing the canopy



    forgot how hard sewing is on the eyes...will continue when I have some better light; then maybe I will stop sticking pins I'm my fingers.

  43. #103
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    done some more of the jobs.
    put in some flooring and covered all accessible exposed bits of the metal chassis



    Sorted out some more of the storage



    and somewhere for paddles



    started to fill it with some reading / reference materials , and other associated bits of my junk that



    and put in a cloths / drying (I can draw air via the vent above – it’s quite fierce being sized for something considerably larger) rail



    all switched and dials and panel to half of door secured and tidied – ran out of wood so bottom of door will have to wait



    thinking about heating and cooking , and I admit a small bit of envy at all the stoves I see people using, I brought this from ebay for £74 (half the price of argos) unwanted gift apparently (it was local collection only and no bids)




    its too tall and on wheels (and quite badly made, I may seem weld it if doesn’t prove to be airtight looks to be folded and spot welded) , and with some modification will I hope prove useful for more than just pizzas (not that I don’t like pizzas) – initial thought was to mount it permanently on to either the back or front of the chassis but after some trials the weight/ balance was just not right so now sized for transport in the trailer foot well (I won’t take it all the time and will put some straps in to stop it jumping around – and may find a big bag if it proves to messy/smelly)



    to pursue the candle power heating option I purchased this (£8 Tesco) shiny brass and wood sort of fitted in with the overall theme



    had another idea, after thinking about how to stop thinks throwing themselves about , so everything needs a place (I keep finding more things) but this proved to be quite messy



    a coat of varnish to seal the foam before a covering of felt.



    but quite pleased with the end result



    might put another lock on the storage..

  44. #104
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    Awesome Steve...great skill and ingenuity. Love this blog and can't wait to see the finished product in the flesh.

  45. #105
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    Yes what a feat this is! Makes mine look basic
    We must get to the same meet next year for sure. What is the estimated weight Steve That is the one thing I worry about with mine...

  46. #106
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    Thanks guys, I don’t know how heavy it is exactly (I will take it to a weigh bridge some time), it is quite heavy with stuff in it as I found out today returning it to the drive after its first trial tow (that was successful ) it rolled back (there is a small slope) I stopped it and something went twang in my calf (think I may have ruptured my Achilles tendon), can’t walk now - so off to A&E - must be getting old, never had that happen before something went 'Pop' and now it pigging hurts, despite an ice pack and medical cider.

    before this incident I made some more small progress.

    With pizza stove in the weight on tow hook is just over 10kg (the limit is 50) so it is quite well balanced without the oven in its a bit rear heavy so I will mount the spare wheel at the front to help correct this





    pizza oven with side flap thing fitted don’t fit that well (why o why o why o why – don’t they give proper overall dimensions – yes it may be W90.5, D59.5cm but when you put the handles and flappy shelf thing on its more like 120 cm x 75 cm.



    took the flappy shelf thing off and turned round and it fits much better (and provides some accessibility)



    now I know this is difficult but if you look closely (in the foreground really look close, ha ha ) the pod has been camouflaged with a rain cover / hide, this has resulted in certain access problems that I will sort out,



    Er and a panel is needed in the top (window from the donor trailer tent) to allow the solar panel to work,



    so more sewing - least I don't have to stand up or walk about to do that.

  47. #107
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    Err.. after 2 weeks enforced idleness - I did tear my Achilles tendon, its getting better now thanks for asking.. I managed to get out for a quick field (hill) test, after what can only be described as major dithering and forgetting how early it gets dark I arrived later (localish lonely carpark end of no through road top of hill edge of golf course - nice view, good for star gazing) than I expected but that was not really a problem



    setup didn't take long (finding how to switch the flash on took longer)



    made a quick bit of dinner (note to self, take knife and fork - then you don't have to eat with spoon and axe)



    facilities all worked fine (no pictures) and a good nights sleep was had, after watching MOTD and testing that the optic dispensed accurately measurements of rum (had to check that a number of times just to make sure)

    quick pack up in the morning and away



    so what did a learn..i wasn't cold, everything worked (except the reversing lights) so all ok, just have to secure stuff a bit better.

    my library didn't survive the journey



    so have made some elastic retainers


  48. #108
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    Very nice - did you sleep with the doors open or shut?

  49. #109
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    kmac, .. there were some coming and goings in the car park overnight, a van/conversion with some Germans arrived very late (not a problem), and various kids (smoking or ####ing I expect) came and went noisily (some set off fireworks), so I locked the door and slept the sleep of the just all nice and snug and secure.

    thanks, you reminded me that i also need to fit catch/bolt on the bottom door so that I can keep that closed on its own.


    you can have a look in December (if I get my marauding weekend pass)

  50. #110
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    An enjoyable read throughout Steve. I loved the problem solving bits you did too. It did feel a little nosey trying to see what books you had. Trees! Birds, and so on. A man after my own heart sort of thing!

    Thanks for sharing and I hope your tendon gets better - as I'm sure it will.
    http://www.davidwperry.blogspot.co.uk/

  51. #111
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    I think you'll need more than 10 kg noseweight to prevent such a heavy trailer snaking. 25 kg would be better.
    After we don't want Sally Traffic telling us about overturned canoes on the M4.
    Do you have brakes?
    Looking forward to seeing it in the flesh at the winter meet (assuming your achilles is better)

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  52. #112
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    Bit of an update
    we must celebrate our failures (as a learning opportunity) as much as we do our successes, and yes you (you know who you are) were right, boxy is a bit heavy- and thought it hasn’t collapsed completely (let’s just say its relaxed a bit) Err the suspension needed some Err more support…so after about 1700 miles too many pot holes, speed bumps, farm tracks and fields - something needed to be done.
    The only damage done is to the 2 removable, replaceable, and somewhat sacrificial mudguards which after inspection were found with holes that are not meant to be there (my idea to make them removable however has now proved its worth)



    so after having a think -massive procrastination, a great deal of self-loathing (for not having done a better job in the first instance – engineers angst) and some wishful thinking (wishing it would fix itself (i.e. stop collapsing and go solid) or wishing for divine intervention (or a mate)to help, but alas no , I finally got my finger out and got on with it – I considered swapping out the whole suspension unit, but in the end decided that was way too much hard work so upgraded/modified what was there, so some mountings and some shock absorbers were required that would fit where I drew these (faint) red lines (old photo) on the existing suspension unit.



    pod up on axel stands so I can get under it



    there is not a lot of space



    the other side – the foam was space filler behind the mudguards



    made some bits – 16 mm steel bar (the same as the existing swing arm) shock mounting plates



    purchased some shock absorbers (600lbs each, 275 Kg, so man maths – 550 kgs of additional support plus the 450kg that existed, should be enough - probably a bit stiff – but it sure aint gona collapse. – these are quad shocks, but my interest was purely the dimensions and rating.



    Plates welded in (and rust protected)



    Err the expanding foam burns well, fast and is easy to ignite (as I found out, I don’t remember it saying that on the can?)
    Clearance, just enough to refit mudguard (I hope)



    the other side ready for welding,



    all done a painted ready for final assemble





    Wheels back on





    it all fits quite tidily, it's tight, but there are clearances (don't know about mudguard yet) so it can all move.



    Time for a road test now, then all apart again to refit the mudguards, after I have fixed/patched the holes .
    So lessons learned;
    if you ever build anything that you are going to tow and loadup more suspension is good, and Err..
    Expandable foam is very flammable (don't do welding without something to put a fire out, however unexpected it turns out to be)



  53. #113
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    Good work there - much more elegant than when I supplemented the pathetic hydraulic rear shocks on my Morris Minor with gas telescopic ones.

    I'm not sure what is meant by those shocks being rated at 275 kg - would that be the weight that would fully compress the spring until it bottoms out? They look like rising rate springs so the weight per inch would increase with load.
    As they're mounted at 45 degrees they will be a bit softer than if they were vertical.
    Is the preload adjustable in case they still bottom out?


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  54. #114
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    Nice one Steve, have you removed the certain plate we talked about at Poole?

  55. #115
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    what plate....?

    Err, yes..600Lbs (270kg)..the supplier said, "what?" then after some time on hold said "per inch" I said, is that progressive? they said "What?", so I thanked the young lady and put the phone down.

    so to test this I held one shock upright in the vice put a rope through top hole forming a loop for foot below vice and stepped in it, shock should have compressed about 10mm, it didn't. it might have moved 5mm but only when I bounced about a bit (thinking about this now - I really should shut the garage door more, anyone passing would have seen me holding onto the bench with both hands, apparently astride the vice moving up and down vigorously?) - did I learn anything, not really.

    I will keep an eye on the new mudguards when fitted (they will be blue - as that the colour of the trug i have, and i hope that this will also make any wear easier to see) and if necessary tighten the preload up a bit.

    cheers
    steve

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