Weather tight plywood box design ideas?

[ctbailey]

Hi everyone. This is only tangentially aligned with Jayco trailers, but I'm interested in crowd sourcing some brainstorm ideas.

The need: an Inlaw of mine comes camping with us all the time. She and her offspring in a tent. We in our TT. She drives a sedan, 2009 chev Malibu. I watch her unload/reload and often volunteer to help in those efforts.

This woman needs an "explorer trailer."

In the most basic sense: a plywood box built upon a flatbed trailer, that will store her hard camping gear, provide space for a cooler, a 20# LP bottle, and finally transport for bicycles.

I'm scouring Craigslist for used utility trailers in the $250 - $400 range.

She needs the storage of camp stoves, mess kits, lanterns, etc. these will live in the box. So, I'm needing to build it weather tight.

My first question to the group: what wood sealing approach would you all take?

1,000 pound GVWR on the trailer according to Chevy manual.
I'm still checking the manual for tongue max.

$750 +\- max budget.

Thanks in advance
Craig

[NC Roamer]

Marine grade plywood with a layer of good caulk between all joints as they are screwed together. Then run a bead of caulk along all the seams and joints when done. That will likely be more watertight than many RVs.

[howlin4you]

If it were me I'd go with something along this route - 78" Tag-Along Trailer - 600 Lb. Capacity

However that may not be big enough. You could buy a larger harbor freight trailer and look for a used cartop carrier to put all the dry stuff in, then make a rack for the cooler and propane tank. If not a cartop carrier a truck bed toolbox or any weatherproof plastic box. It could all be well under budget, completely waterproof, and durable. Actually sounds like a fun project. Anyways, I know that isn't exactly what you asked for but its just my .02.

[ctbailey]

Thanks NC. I was also pondering some sort of wood sealants, or maybe a layer of resin? I can't wait to see how much a marine grade sheet of 1/2" or 3/4" will cost.

[Tunce the traveler]

How about something along this line.

[ctbailey]

I'm open taking an open mind approach to this project. [emoji3]. Any and all ideas are welcome.

I'm thinking the darn bikes are going to be a controlling factor... Both in size and budget. The super nice trays and roof mounted systems can fetch my entire budget if bought new. Craigslist is my friend.

[NC Roamer]

Originally Posted by ctbailey

I can't wait to see how much a marine grade sheet of 1/2" or 3/4" will cost.

It will definitely be more expensive than subfloor-grade plywood, but you know how RV owners abhor delamination!

[Crabman]

Well in the seafood industry I and others have made a plywood truck body using regular exterior plywood and 2x4`s for frame for the back of a pickup to haul seafood around in and they lasted for several years. Don`t see why it would not work on a small flatbed as well, we just caulk the joints good and paint the body. This might work into your budget requirements.

[ctbailey]

Excellent! There is nothing more severe than the marine environment. Thanks for the experience.

Wisdom is what you get from reading the textbook. Experience is what you get from not.

[need-a-vacation]

Craig,

If you had to guess, what size storage box is needed? My intial thought was a rooftop carrier as well. Or a full size p/u bed tool box.

If you could find a trailer similar to the HF 4x8, maybe mount the box in the center, front to rear, with a bike on each side?

Does the budget include a hitch for the Malibu?

Another option to seal the wood (depends on just how big the box is) is to use the resin for fiberglass (no fiber), and coat the box with it. May be a little more now, but should last a long time without much need for upkeep.

So another crazy thought that may keep the cost down a little for now (upgrade when more money allows). What about building a nice frame, but using a truck bed liner for the sides if you can get one (or two) for free? Hard part would be making/keeping it water tight....

Or is there a large enough Rubbermaid tote (or two) that would be big enough, and stay within the budget???

[ctbailey]

OK, I have been spending way too much time thinking on this... I'll try to upload some of my hand sketches to show what I'm up against.

(I've been sketching in a memo notebook, and I didn't bother with a scale.)



The gross exterior dimensions I've come up with so far:
51 1/4" Wide x 76 1/4" long, by 18" tall

Those numbers came from topview1:


and the side view:


and the tail view:


SO... envision a plywood box sitting on a flat deck. The front 2 feet is an open deck with expanded metal, surrounded by stake sides. The back 6 feet is an enclosed box where the top hinges open at the sides, creating two tables running the length of the box. These tables when open, will support the coleman stove, etc. When closed, the (4) bikes are mounted using front wheel fork mounts. I'm thinking of using PVC as the "trays" to align the bikes. 2 bikes face forward, 2 bikes face backward, to minimize handle bar collision.

So - that's what I've come up with.

The hitch on the car is not included in my "budget."

[ctbailey]

Maybe I should have posted an actual AutoCAD drawing...

But the hand sketch is still needed even if a person intends to properly draft it.

I'm thinking this unit is my canvas... waiting to become art:
Utility Trailer 6' x10'

BUT!!! I can't believe my eyes:

http://www.harborfreight.com/1720-lb...res-94564.html

Its sad we can buy new $50 cheaper... although the new one comes totally naked without any decking at all.

[SMS1115]

When making repairs to wood boats, we use the West System epoxy on the edges of the plywood to seal the ends from drawing in water and rotting the wood from the inside out. Caulk all seams, then a good coat of Marine grade paint should do the trick.

[ctbailey]

Originally Posted by SMS1115

When making repairs to wood boats, we use the West System epoxy on the edges of the plywood to seal the ends from drawing in water and rotting the wood from the inside out. Caulk all seams, then a good coat of Marine grade paint should do the trick.

Thanks Steve. I will definitely check that stuff out!

[ctbailey]

West systems - looks awesome, but YIKES they don't give that stuff away. I'd be looking at a gallon of the resin, and about a quart of the hardener. I'm thinking the outside surface as well as the raw ply edges should be sealed?
Amazon has a kit for $151: http://www.amazon.com/System-Epoxy-q...t+system+epoxy

But... if it means I'll never have to build another gear trailer, I'm in.

[need-a-vacation]

With the lids having a seam down the center, what is the plan to seal the lid when closed so water doesn't get in?

What about a one piece top, but maybe use an aluminum roll top table (or two) for the camp stove and water station? Can move them as needed that way. Easy to store like a bag chair, and fairly lightweight. Just a thought....

Keep us posted on your project!!!

[Poppy]

What about making the box of plywood and coating it with bed liner type paint? You used to be able to buy it at Walmart.

[ctbailey]

Need: that center seam I imagine will have a lap piece, so you would need to open one side first. I'm looking into rubber seals that I can brad nail, to create good seals.

I'm not married to having the work surfaces, and it looks like the hinges will be tough to source. (I use that cabelas roll top table you speak of for MY camp stove When camping in the 32BHDS).

Poppy: yup. A can of roll on bed liner is absolutely in the works. I'm even considering it to coat the OUTSIDE surfaces. But I'm loving the West Systems epoxy to seal the edges of plywood panels.

These ideas are just what the doctor ordered! Keep em coming!

Crowd source design at its best!

[RUSSELL5000]

I suggest that once you have your box design down and built that you cover the tops and ides with one layer of fiberglass cloth and epoxy. Go to Clarkcraft.com for cloth and epoxy at a much lower price than West system, or epoxyproducts.com.

Sand lightly to scuff up the surface after full cure and cover with a layer of white Herculiner bed liner. This will protect the box.

The only thing is to think how you will keep the box opening weather tight.

[RUSSELL5000]

P.S. - if you use fiberglass cloth and epoxy then you can use regular pine wood and plywood for the structure. I have built all kinds of things for my sailboat out of soft pine that I covered with cloth and epoxy.