She Rises!

I installed the inner layer of "caravan ply" while the sides were still flat on the table.  I used Gorilla Grip glue and air driven staples where they wouldn't be seen.

I made a temporary right angle brace to support the sides while the roof is being installed.

At last I get to see what it will look like.  The side panels are screwed and epoxy glued to the base.

The first five roof beams are fitted into their notches and held with a screw and thick epoxy glue. 
The outside of the side panels were sheathed with fiberglass before they were put up.  Glassing a vertical surface is no fun.

Sandwich walls

 The perimeter of the side panel has a 45 x 45mm laminated beam with a break at the hatch hinge.

 Inside framing was installed with 20mm polystyrene insulation filling in the spaces.

I cut notches in the laminated beam for the roof beams.

Side profile

My teardrop is 3 x 1.5 metres or 5' x 10'.  I drew the profile on my CAD program and proceeded to duplicate it on the plywood sheets.

It is possible to buy three meter sheets of marine plywood but the price increase was too much, so I'll have a butt block splice back in the galley.

The foundation

I had the trailer frame made up by a local engineering shop.  It was plain steel when I got it and I applied two coats of two pot epoxy primer (used on steel ships) and two coats of epoxy enamel on top.

A winter project

Since discovering teardrop camper trailers last year, I've been determined to build one for myself.  The shape is elegant and efficient so how could I resist.  As a retired professional boatbuilder, I'll be using construction methods more akin to boatbuilding than what is shown in most plans.  My methods are not necessarily easier, but I feel more comfortable with them.