Lozenge camper

Self builds and DIY projects
keeflester
Posts: 538
Joined: August 24th, 2014, 8:23 pm
Location: Carradale Argyll and Bute Scotland, beside the sea

Lozenge camper

Post: # 3841Post keeflester
February 2nd, 2015, 8:30 pm

Not strictly a Demountable camper, but the techniques involved in building the lozenge are transferrable to any style of body. I'm building in plywood over softwood frames because that's what I know and can achieve. I'm still struggling to figure out how to post pictures on this forum since I don't use a pc and the various options for iPad are not very intuitive to use, or downright useless. So just for now until we can figure out a better way, I've started a thread on our Facebook page.

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add these in here for now Keith;

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2003 Ford Ranger 2.5 TD 109 Supercab, sold to Simon
Tandy Pony, sold
Northstar 750, sold
K33F-built Penthouse Pee Pod, sold to Simon with the Ranger
Built the lozenge for my wee sister, its now finished and in regular use
Now converting a blue Tranny.

keeflester
Posts: 538
Joined: August 24th, 2014, 8:23 pm
Location: Carradale Argyll and Bute Scotland, beside the sea

Re: Lozenge camper

Post: # 3849Post keeflester
February 2nd, 2015, 9:27 pm

First picture shows the 12mm marine ply subfloor on a sub chassis made from treated 2x2. I painted it with bituminous paint before turning it over and bolting it down to the trailer chassis.

The height of the door created difficulties since the original idea was to use a single sheet of ply for the wall. To make enough room for its frame I added a valance of 12mm marine ply. This meant that I had to cut steps into the vertical frame members.

Once the frame was built I used ratchet straps to pull it all square and screwed in temporary braces.

The first side is the most fiddly, two apertures to cut. I fitted the sheet dry with screws. Once all the skins are on and they fit ok, I'll glue them in to get the monocoque strength. The screws will not show, I placed them close to the edges so they will be sealed under the corner trims.

Thanks to Zildjian and Andy for hosting the pictures.
2003 Ford Ranger 2.5 TD 109 Supercab, sold to Simon
Tandy Pony, sold
Northstar 750, sold
K33F-built Penthouse Pee Pod, sold to Simon with the Ranger
Built the lozenge for my wee sister, its now finished and in regular use
Now converting a blue Tranny.

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zildjian
Site Admin
Posts: 22052
Joined: September 8th, 2013, 3:30 pm

Re: Lozenge camper

Post: # 3869Post zildjian
February 3rd, 2015, 5:20 pm

Would it have been viable to take door below floor level with a locker underneath only accessible with door open,
then use standard width ply up to roofline?
might have been a handy place for the less popular stuff, out of the way

keeflester
Posts: 538
Joined: August 24th, 2014, 8:23 pm
Location: Carradale Argyll and Bute Scotland, beside the sea

Re: Lozenge camper

Post: # 3873Post keeflester
February 3rd, 2015, 6:51 pm

zildjian wrote:Would it have been viable to take door below floor level with a locker underneath only accessible with door open,
then use standard width ply up to roofline?
might have been a handy place for the less popular stuff, out of the way
We discussed that but Jackie wants a simple job, no frills and the lowest height possible (for mpg). Also, the weight of her previous teardrop camper was an issue for manoeuvring on her gravel driveway. I propose to run the cabling in the floor void, so underfloor storage would rob sitting up room.
2003 Ford Ranger 2.5 TD 109 Supercab, sold to Simon
Tandy Pony, sold
Northstar 750, sold
K33F-built Penthouse Pee Pod, sold to Simon with the Ranger
Built the lozenge for my wee sister, its now finished and in regular use
Now converting a blue Tranny.

keeflester
Posts: 538
Joined: August 24th, 2014, 8:23 pm
Location: Carradale Argyll and Bute Scotland, beside the sea

Re: Lozenge camper

Post: # 3875Post keeflester
February 3rd, 2015, 6:54 pm

Sides and back are on. I trimmed the edges flush and overlapped each sheet over the edge of the previous sheet.
2003 Ford Ranger 2.5 TD 109 Supercab, sold to Simon
Tandy Pony, sold
Northstar 750, sold
K33F-built Penthouse Pee Pod, sold to Simon with the Ranger
Built the lozenge for my wee sister, its now finished and in regular use
Now converting a blue Tranny.

User avatar
zildjian
Site Admin
Posts: 22052
Joined: September 8th, 2013, 3:30 pm

Re: Lozenge camper

Post: # 3880Post zildjian
February 3rd, 2015, 9:53 pm

Is there a trim to go over those as well, like awning rail or something

keeflester
Posts: 538
Joined: August 24th, 2014, 8:23 pm
Location: Carradale Argyll and Bute Scotland, beside the sea

Re: Lozenge camper

Post: # 3883Post keeflester
February 3rd, 2015, 10:40 pm

zildjian wrote:Is there a trim to go over those as well, like awning rail or something

Yes, I'm using CT1 to stick a corner moulding over every exposed bit of end grain. Unfortunately, I wasn't able to get the smooth rounded over corner mouldings I wanted, so I'm using squared corner beads. I'll take the arris off each piece before I use them and then sand the corner to a soft profile. CT1 has the double properties needed, it's a good waterproofing seal, and it takes paint once it's properly dry. Silicone sealers just don't take paint.
2003 Ford Ranger 2.5 TD 109 Supercab, sold to Simon
Tandy Pony, sold
Northstar 750, sold
K33F-built Penthouse Pee Pod, sold to Simon with the Ranger
Built the lozenge for my wee sister, its now finished and in regular use
Now converting a blue Tranny.

User avatar
zildjian
Site Admin
Posts: 22052
Joined: September 8th, 2013, 3:30 pm

Re: Lozenge camper

Post: # 3884Post zildjian
February 3rd, 2015, 10:43 pm

does that allow any movement of the wood below it like a silicone bead

keeflester
Posts: 538
Joined: August 24th, 2014, 8:23 pm
Location: Carradale Argyll and Bute Scotland, beside the sea

Re: Lozenge camper

Post: # 3885Post keeflester
February 3rd, 2015, 10:48 pm

zildjian wrote:does that allow any movement of the wood below it like a silicone bead
Yes, it's a flexible product and I've used it extensively in my work. It's advertised as the single solution to all your sealing jobs. It costs about 5 times as much as regular mastic, and it is worth it. :o
2003 Ford Ranger 2.5 TD 109 Supercab, sold to Simon
Tandy Pony, sold
Northstar 750, sold
K33F-built Penthouse Pee Pod, sold to Simon with the Ranger
Built the lozenge for my wee sister, its now finished and in regular use
Now converting a blue Tranny.

User avatar
zildjian
Site Admin
Posts: 22052
Joined: September 8th, 2013, 3:30 pm

Re: Lozenge camper

Post: # 3886Post zildjian
February 3rd, 2015, 11:00 pm

Could you (when you get to it) do one or more close-ups of exactly how you typically fit that

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