RE: Pop Up Trailer Conversion
 

Hi all,
Got back in town tonight and went ahead with gutting the rest so I can get to the fun part... re-building it!! Here's the latest view. Yuck!! [:'(] The back panels were so bad I just ripped them out. I think the rest of the sidewalls are good enough to leave in place. If I can get a majority of the vinyl to come up I'm going to bleach down the floors and sidewalls (as well as the exposed back areas...) and do my best to dry it up. I need to get underneath and rip a bunch of tubing (gas/water) out so it won't fall off inconveniently on the road :D... Also need to come up with a plan for re-routing the power lines... either behind side walls or maybe just down through the floor and back up so that they are out of the way or at least protect them with conduit or the like... not sure yet. I know I want them around! Having power already distributed around the trailer can't be bad!! [8D] Picked up a converter so I can plug the lighting up and test that whenever it's convenient. Also got 2 of the 3 cables I need to fix the lift mechanism and some lubrication for same. 3rd cable will be mailed to me soon. Still have the fridge and kept the counter top so may re-use those once I test to make sure the fridge works! Also planning on keeping the overhead lights and re-installing a switch to turn them on/off near the door so if I'm loading or unloading near dark I can see what I'm doing. Lots more stuff running through my brain... sealing up the lid so no more water!!! How/what type of storage to install... What sort of enclosure/where to hide the battery/inverter... etc... etc... etc...
One question for you all... What should I do for tie down points once I get the new floor/sidewalls in place?? I considered an L shaped piece of aluminum (well probably at least 2) running front to back the length of the trailer. I've seen it with holes every 1/2 inch or so big enough to accept all sorts of hooks/bungees etc... Turn it open side dow and run a screw through it every foot or so and you have lots of tie-down pts... bit of a trip hazard but not sure it would be a problem and I want something flexible... Ideas welcome!

Second question... What sort of wing rack should I build? Planning on something that is up in the lid. That space is at least 6 inches deep and I want something flexible to store all sorts of wings as well as sturdy and protective of the wings. Will need to include good tied downs of some sort and maybe a way to pivot it down for easy access?? More ideas needed!

Enough for now. I'll keep you all posted as progress is made.

RE: Pop Up Trailer Conversion
 

You could go down to the local ace hardware store and buy a few handles that fit the sides of a trunk. They fold down when you let go of them when lifting a trunk so they would probably fold down onto the floor when not in use. Just a suggestion, may or may not work for you. They have a lot of different style handles, you find a different one that works better.

I've been following your thread with interest as I may need do something simular.

RE: Pop Up Trailer Conversion
 

Well I've been to the lumber yard and chewed a couple hundred bucks up on plywood, some smaller stock and some adhesive, caulk, screws and the like. Started to put some of it to use repairing the worst of the water damage in the rear of the trailer. The hardwood that makes up the frame on the back was mostly gone so replacing it was the first step to rebuilding this thing. also had to add some extra wood to give me something to attach plywood to once the liquid nail dries that is holding this together at the moment. I think once the stuff dries I'll be ready to cut a piece of ply to lay across the back and screw in place. This may be the one place I use some adhesive to attach the ply as well to make sure the structure of the trailer is maintained back here. Once the ply is in, if it looks like I'll have the space (need to leave enough space on those uprights to attach to with the wood coming down the sidewalls) I will cover the ply with Luan to give me a nice interior finish. The rest of the walls will be Luan (over the existing wood so structural strength is not an issue) and the floor will be raw ply since I intend to carpet it (cheaply) anyway! As you can see I had to remove the tube holder (bed supports etc... were stored in here from outside) to make my new structure fit but I couldn't figure a good use for that anyway since the lid was broken and so it was just another water entry point. Good riddance! Hopefully will have more for you all soon.

RE: Pop Up Trailer Conversion
 

I have a 13ft inside that I converted a couple years ago. now that you took all the stuff out be sure and check the outside walls for being ridged. I had to put some plywood triangle braces back in to hold the walls in place. the walls were held by the cabinets and appliances. They would flop back and forth in the wind with nothing inside...


I have room in mine for two third scales put together and several other models taken apart.

I would try to post picts but the digital camera is 100 miles away taking pict of my grand children..

Don//

RE: Pop Up Trailer Conversion
 

Don,
I hadn't mentioned it but have noticed the same thing... at least on the right side where the door is. I am planning on reinstalling some counter space and storage boxes that will (I hope) also re-establish the rigidity of that right side wall. Between that and building a new "box" inside the box I think I'll be OK. Thanks for the tip. When you get the camera back post some pics! Always looking for good ideas.

Jack

RE: Pop Up Trailer Conversion
 

You might get some of that "Under Coat in a Can" and spray the bottom of your floor before you put it in. It will help from any future rot and might be easier to do now than later.

RE: Pop Up Trailer Conversion
 

Well I have made a bit of progress today. Got a piece of ply cut and mounted - screwed and glued to the back "U" frame I built in rear of the trailer the other day. Also got the first piece of ply placed in the floor. The problem with that was because of the old wood rot/missing I didn't have enough left in places to get a proper bite and the new ply is not perfectly flat, nor would I expect it to naturally lay flat considering the weather extremes it's likely to see anyway!! My ingenious [&:] (I hope) solution was to glue the sides of the flooring to the old wall boards and rear 2x2 base to my frame and then add some temporary bracing that I will pull out tomorrow and hope for the best. If this doesn't seem to be totally effective I may go back (and have considered doing this anyway) and add some wood at each joint (like quarter round but probably will use something in the 1x1 - 2x2 range) and glue and screw that to really reinforce things.... we'll see. For now the next steps are going to be to finish the floor with ply and start working on the sidewalls with the Luan. Once it's all in, I'll seal all the joints with either silicon caulk or caulk-adhesive if I feel some strength is needed. I need to start making some covers for the lifters in each corner. There were hardwood blocks across these that seemed to actually be structural and maintain spacing so that the lifters didn't bind but some were in bad shape so I'll replace them all. Plus some ply/luan cut to size for "modesty covers" that I presume are just to keep things from getting into the tracks that don't belong there ;).
I may just bond some Luan to some ply to make full length covers all in one piece with some hardwood strips glued on if I feel the strength is needed... Probably need some pics to explain properly so will do that when I get to that point. Anyway, here is where it sits for tonight. Looking forward to pulling the temporary bracing (wax paper underneath it to make sure it stays temporary!) and see how this is working out.

RE: Pop Up Trailer Conversion
 

Wish I'd read your post on the undercoat thing BEFORE I glued and screwed those first two pieces in place! The rest of the floor is in much better shape so won't likely have any problem. Oh, well. Live and learn. If I'm back doing this next fall again because of Rot or mold problems I guess I'll do that! I'm hoping a good heavy coat of Kilz (or two) will discourage that for a long time to come. That and of course re-sealing all the edge joints on the pop-top where it appears to me things must be leaking and anywhere else I suspect water will get in.

RE: Pop Up Trailer Conversion
 

The floor is in and I think it is going to work out OK. My glue set up and is holding up well. I walked around the edges up against the glue joints and nothing moved. :D The wood gives just a bit when you walk on the floor (not enough to see but it feels like it is somewhat cushioned) but much less than it did when I got the trailer and I think it will work out OK. Here are the pics at the current time. I need to start on the Luan for all the side walls next but my eyes are tired from all the measuring and cutting today so will put that off 'till tomorrow at least. If I do anything else tonight it will be to install the new marker lights, check the electrical, or something minor like that. Enough physical labor for one day! I knew there was a reason I went to college. ;) Probably should have patched all those little holes going through the floor before I laid the wood down but why start thinking ahead now [sm=wink_smile.gif].

I also need to do some caulking around the wheel wells and such but I'm thinking I may wait till I get all the lumber up and then go fill all the gaps at once right before I undercoat it all. Might need to install whatever cabinetry is going to be permanent before I do that as the gap between the sidewalls and the wheel wells varies widely when the walls wiggle around. Hopefully those will get stabilized when I get some of the sidewalls "Luan'd" and those cabinets in place.

RE: Pop Up Trailer Conversion
 

More progress today. Finished sheeting the right sidewall and installed new hardwood blocks to keep the lift mechanism in their pockets. Those little blocks also help stiffen up the hole structure so I bought some hardwood and created new ones for all 4 corners. They definitely make a big difference. Installed 3 sets and left the 4th for after I fix the lift cable on that corner. Here's a couple snaps of the results for today. Takes a while to do this (well for me anyway [&:]). I measure 3 times, cut once, trial fit, cut again and repeat... I always cheat a little toward to big and sure enough it is! I've never figured out how to stretch lumber though so beats cutting to short I guess. Still debating on how much storage I will need and how much I need just to help reinforce the sidewalls! Bolar had a good point when he mentioned how weak they are without the internal structures to hold them up. I'm pretty settled on a 24"wx36"lx18"h structure front left to hold the battery, inverter/charger system. That will hold all the stuff and have some extra room for storage and whatnot. Might event put drawer back in right above it so might be more like 24" high. Front right I need to do something because that is the weakest wall plus it has that external access hatch that might be handy. The opening is about 12" tall by 30" long. Might just build a box about 18" or wide and install that... maybe without a top so access is handy from inside as well... or maybe with a true lid that can be opened. Back right I plan on re-installing most of the countertop that was here. I can see setting a plane on it and then climbing in the trailer and grabbing it to sit it down on the floor. Leaning over the wall to do this is a stretch for me. If I put the counter in just an inch or two below the top of those walls and maybe put a slight lip around it... I think it will come in handy for a lot of things. Underneath could be left open or partly enclosed for storage... Maybe a spot for pop-up under there?? Partly will have to be determined by the need for support of the top. Certainly that will make the wall on that side stiffen up.

RE: Pop Up Trailer Conversion
 

Got back on it today and first order of business was to pull the bad lift arm and recable it. I found it interesting that there is nothing that really holds those things down except the cross brace at top interfering with the pulley. Guess there's really no need for anything considering the whole weight of the top holds it down and they sit right on a frame member below. Here's a pic with the lift mechanism removed. Just a framed up wood socket really. Got the internal cable connected and routed the one from under the trailer up into the lift mechanism. Need to attach the final cable to the winch and I'll be back in business on the pop-up part of trailer.

After lunch I wnet back to work on the interior walls and flooring. Added a little glue where there are gaps or edge to edge corners where there is nothing to screw to and will let it dry for tonight. Feels good to get that taken care of. Now I can start working on counter top... storage cabinets and the like. Making progress! [8D]

Also spent a little time underneath and pulled all the remaining copper gas lines and took a quick peek at the winch mechanism. Looks like it might be a bear to get that cable hooked up where it belongs as access is limited and the old cable looks like it's balled up around things in the winch. I'm thinking of jacking up the whole rear end and putting the thing on some jack stands to give me some more clearance to work on it and see if I can get in there and get rid of the old cable first. I'll try to get pics if I get some space to work!

RE: Pop Up Trailer Conversion
 

Hi all,
Took a break on this while my sister-in-law had open heart surgery... two valves replaced etc... She's doing great, just went home today. Anyway, I got some time to work on the trailer today. Got to work re-installing some of the counter along the right side and also the externally accessible storage box was re-built. These structures helped stiffen up the sides and I did my best to get everything as square as possible and I feel like that worked out pretty well since the door and outside hatch to the storage area seem to open and close smoothly now and the whole trailer feels much stiffer. :)
I need to finish up the storage box as you can see in this first picture. Probably will re-install the door on the end that allows access from that direction as well and not sure yet if the sides will just enclose it or if I'll build them up a bit higher so that I can use the top as a tray/shelf for stowing transmitter boxes or other items... I don't intend it as a seat anyway so might just as well use that space for something! Also will probably finish enclosing the wheel well under the counter with a front panel so as to make it neater and give me a place to mount the AC outlet over there. It's just hanging at the moment.
One more "box" to build on the left front to house the battery/inverter/cord plus I'll probably build a cabinet around the other wheel well as they are kinda flimsy and if someone put their weight on it I think it would dent badly and possible interfere with the wheel... that would be bad. [&:] Also picked up some plastic race/conduit stuff to hide the wires on the other wall and protect them from damage. Will wait to install that 'till all the rest of the construction is done inside... right before undercoating starts.

RE: Pop Up Trailer Conversion
 

Made another push on the interior today. First two photos show the new power center in the front RH corner. Top is easily lifted off to service fuses, battery etc... The battery box has a hole out the bottom (just like when it was a camper) and a vent out the sidewall to allow for airflow during charging. Need a new vent hose and have to sort out the battery hold down but otherwise this is looking pretty good. Next two shot show the new radio storage box in the front right corner of the trailer. there is a door on the back to access things from inside or you can come in from the outside. Things are a bit tight but I can get two radios, in their cases in plus some excess space that I'm sure I'll find a use for! I figure if I need access to anything without cranking up the lid it will be the radios as I might just want to grab an electric from the garage and throw in the back of the car or truck and head out if time is tight or whatever. Especially since that hatch is lockable, it seems like a good spot for the expensive stuff! Next is a shot down the left side showing off the new "plastic conduit" to neaten up and protect the wiring running down that wall. Finallyis a pic showing the outlet under the counter mounted and the wires hidden up underneath. There's still a long list of items on the todo list but today I actually feel like I am starting to see what it will look like and I'm pretty happy so far [8D]. Won't be long and I'll have to do a bit of finish sanding on some corners, caulking and paint, carpet etc... etc.... :D

RE: Pop Up Trailer Conversion
 

It`s staring to come together . Looks good.

RE: Pop Up Trailer Conversion
 

Here's a suggestion for interior lighting that is cheap and very effective. Look around your local Big Lots discount store (or whatever name is in your area right now for white LED Christmas lights. I bought several 25' strings for about $6.50 each, plus a 70 watt cigarette lighter size inverter. If you install them with a little care, you won't show any wire and 2 strings inside the cargo area of my Dodge Sprinter van lights it up like crazy with almost no power drain and no heat buildup from the lights. When I got through, you can't tell that it's not some custom interior shop job. As you know, LED's last forever, and so far, vibration hasn't damaged them. Also, if you're of a mind to use "rope lights" they have them cheap also, but they don't put out as much light.

Roy

RE: Pop Up Trailer Conversion
 

Any progress? :D

RE: Pop Up Trailer Conversion
 

Between holidays and working on my new WH 28% Edge this project has gotten a bit stalled. Will post again when I get back to it. Thanks for asking. With the weather turning cold (and considering the garage is not heated) I'll have to work around the temps and the upcoming holidays. Hopefully can get back to it soon.

RE: Pop Up Trailer Conversion
 

Hi all
Just in case you'd given up on me, I finally found the time and with the help a little spaceheater and some heavy coveralls I have re-started the project! Today I finally replaced the final piece of cable so that I can raise and lower the top without assistance!!! :D I had to drop the winch down and pull out the old cable and then replace. Not a complicated job... just a bit tricky at times due to limited space under the trailer and the limits of my jack and jackstands. I'm left with a slight misalignment with how the lid sits at full down but I think I know the cause and will be able to take care of that problem when I get around to it. Might even seal as is but I don't want to take chances on a leak after all the work I'll have in this by the time I'm done;). When I make some more progress, I'll write more and furnish a few pics when significant progress is made.

RE: Pop Up Trailer Conversion
 

Hang in there on your project ! Life takes detours at times, but you will see the fruits of your effort littel by littel.
RACE 66

RE: Pop Up Trailer Conversion
 

Great to hear you are back on it. I will get a picture to you on how I changed mine. I think that I have all of the wiring issues settled. I am going today to pick up the material we discussed over the weekend. I will make a list after I get it home of what is really there. However I will copy you on the original email with a partial list.

You had also mentioned that you may consider putting a motor on to lift the top. Any idea on what it would take? I have several different types and sizes available from dad's stuff if you want to experiment :)

RE: Pop Up Trailer Conversion
 

Little by little I'm making some more progress... Here are some new pics showing how I patched over all the holes left behind by appliances etc... Also wire-brushed and did some rustoleum undercoat on all the bumpers tongue and spare bracket etc... I had planned on painting black on all of that but now not so sure. I'll either just go a second coat with the undercoat or find a nice brown as the undercoat color is actually a better match than I think black would be! You may also notice I completely replaced the safety chains that were really corroded (not much use if they won't hold in a pinch) and put a new wheel on the jack so it would roll much better than it did. That was a bit of an adventure as I had trouble finding a wheel the right size and able to handle the load without immediately developing a flat spot, etc... but I think I have a workable solution now. Seems to work fine. I'll keep updating. Hoping to do some more calking this afternoon and hopefully start on some more interior work soon.

RE: Pop Up Trailer Conversion
 

Hi all,
Well, frustration with not having a trailer has finally overridden all else and I've been making time to work on the trailer again[&:]. Since I last posted I have done several of the remaining "necessary" projects and decided to postpone those that can wait in favor of what's necessary to make it workable. If I don't get my planes out of the way of the work in the shop soon I'll destroy them all just trying to get around.
So I have replaced the taillights, all 5 amber markers (all of them were so brittle you couldn't open the covers to replace a bulb) and re-wired the lighting connection to the vehicle up front to something that was made this decade and can be matched up! Inverter/charger is non-functional [:o] but I have a deep cycle 12V on board and can live without the charge piece. I also own 2 inverters so will figure out later if one gets installed permanently or what. That takes care of electrical for now.
My wife assisted my in painting the interior [8D] and I have about 2/3rds of the carpet in place now (tonights project, but ran out of daylight). Also have a wing rack in place in the ceiling area (from PVC) that should handle pretty much the entire fleet at the moment.
Also pulled one wheel and examined the bearings and electric brakes and they appear to have been well cared for and in great condition. Tires look pretty good too. Only oddity is that I can't figure out how to get the tires off without deflating the tire first and then a major wresting match ensues because the tire will not fit between the hub and wheel well to get it off! [X(] I'm really screwed if I have a flat!!!
I don't have electric brake connections to the truck right now but will consider it in the future. Trailer is a lot lighter than it used to be so don't feel like it's a big safety issue, especially as few highway miles as I'll be putting on the beast.
Also sealed the whole trailer up tight (especially the lid) with either silicon caulk (side areas) or that self leveling sealant they make for RVs (lid). It's been parked outside now through a couple thunder storms and shows no signs of leakage except a very minor drip around the door that begs for a new seal on the door top. That will get fixed soon.
Anyway, that's about it for now I think. If I can save a few bucks to buy the last few pieces I need this thing could be carting airplanes in a couple weeks. Thanks for the email and PMs I've gotten asking about the project. I'll try to post some pics soon to give you an idea where it's at.

RE: Pop Up Trailer Conversion
 

Hello Jack, I had the same issue with my trailer with not being able to get the wheels off. I discovered that I could remove the dust cap off of the hub and it would squeak by. I looked for shallower covers but could not find any.

RE: Pop Up Trailer Conversion
 

Well the trailer is loaded and ready for it's first trip to the field. Possibly later today! :D I have a few things left to do before she's really "finished"... if there is such a thing. But it's loaded and road-worthy at this point anyway. Here's a few more pics to give you an idea how it came out. Still things I need to finish up or things I want to fix/change but nothing to serious.

Excuse the blanket over the airplanes but it gave me any easy spot to toss in the T28 until I rig a better spot for it to hang in the lid... maybe... Probably will be joined by the little flat plate foamy (currently just lying on the floor up front, tucked under the Knife) and perhaps the Aito (which is still in the garage). The Aito is so light and fragile I need to see if anything shifts and how things ride before I find it a safe home in here.

So in the trailer at this point is My Telemaster 40 (currently on floats and hidden under the blanket); an old semi-symmetrical high wing that is my "glider chaser" for those flights where I figure I own to many airplanes ;) and there is a good possibility of a non-return to base leg; a GP 160 size Extra; a Morris the Knife; the two foamies as well as my pop-up, flight box, assorted tools, Li-ion powered dremel, my transmitter case and general tool case (last three all accessible from the outside hatch)... etc... The frist three have their wings stored above.

I'll update on occasion as I fix/modify things from here but the main project is pretty well finished up for the time being. I'll be happy to answer questions and/or post pics of anything your interested in. See y'all at the field.

RE: Pop Up Trailer Conversion
 

Nice job[sm=thumbup.gif]. In the winter do you plan to store your planes in the trailer or bring them in?