This is our Weekender Trailer.  page 6

Build demo: the plywood and the wood strips.  I get a lot of questions in regards to the building technique.  I hope the picture will help (or confuse)  

wood strips are fastened with adhesive to the plywood and screwed from the exterior side.  It is important that all joints and edges be glued.  The surface area for contact is greatest this way.  The screws help to hold the strips in place until the adhesive sets.  Believe me the adhesive makes a strong joint. Notice how I allowed a set back equal to the thickness of the plywood.  This will allow the end sheets and other sheets to be applied.  A little thought process here goes a long way

This is a composite shot of all layers. To add strength, I glued the interior paneling to the strips and tacked it in place with finishing nails. Insulation foam placed between two strips

As you can see the AC opening is quite simple. The metal flashing is around the opening to prevent the gasket from sticking to the paint (learned the hard way – I almost never got it open the first time) I can use the chain to adjust the angle of tilt for the AC.  The hinged door then becomes the support for the AC. I seal around the unit with foam rubber

underside of trailer with wiring

The flashing was bought at Lowes and is regular 1 ½ X 1 ½ roof flashing.  It is sold in 10 ft lengths @ about $1.92 a stick. Before attaching the flashing around the edges, I applied some peel and stick asphalt – butyl sealant tape.  This tape is commonly used for roof and gutter repair. It has an aluminum backing and will seal when a screw goes through it.  A roll is about 6 inches wide – so you can cut it half and double your roll. Also used it to seal the entire wheel wells. I used some fancy flat head sheet metal screws to hold the flashing since these would be seen. 

 I apply the tape to the corners and seams first – cutting it slightly smaller than the flashing.- with the aluminum facing outward.  Then I screw in the fasteners.  They are stainless screw with a self-tap on the point so no pre drilling is necessary.  The screws go through the flashing and the tape providing an excellent seal.  If done correctly like I have shown in the pictures, the plywood, adhesive, screws, peel and stick tape, and flashing will provide a strong, waterproof, redundant joint.  

 I do not have a shop – only a garage in which I have to pull out one of the jeeps to work in.  The only tools I used were a jig and skill saw, drill, clamps, hammer,  large scissors, a knife and an assortment of other hand tools.  I say this to inspire others to get involved and start building.  Nothing is better than to say “I built this”. Just a little planning at this stage goes a long way. There are many ways you can finish your exterior. I filled the gaps and did a light sand job – remember I built mine on a budget.   The one thing I wanted was to keep the cost and the weight down. I have added a strip of sheet metal to the front of the camper – it seems that Jeeps like to throw a little mud on the trailer. It will make it a little easier to keep clean. I must admit that I do not take my Jeeps on the trails as much as they need to be! But the open road with the top off and camper in tow– now that’s Jeepin!

Good success with your build.    

Teardrops and Tiny travel Trailers Forum, with good advice and free downloadable plans: www.mikenchell.com/forums