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Food      Living       Outside        Play        Technology       Workshop

Gypsy Wagonby jaylabrosse on August 21, 2014

Table of Contents

Gypsy Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Intro:   Gypsy Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 1:   Build your Harbor Freight trailer ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Step 2:   Build 4x8 box out of 2x12s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 3:   Floor subframe is 2x4s .. you could just slap a 4x8 sheet on this but I was afraid of deflection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 4:   Add 3/4 plywood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Step 5:   Screw it all down with exterior grade deck screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 6:   I added the ledges first but in retrospect I should have done the gussets first. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Step 7:   Add you own flare here ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 8:   Screw and glue all gussets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 9:   You could stop here and have very cool wagon lol! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Step 10:   Time to transfer your drawing from that napkin ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 11:   Cut out your shape ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Step 12:   King pins installed now hang your cut outs on the king pins and screw them down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 13:   Front and back walls are hung . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 14:   Side frame is 2x2s 16s on center. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Step 15:   Dont forget to cut these notches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 16:   Fit roof stringers I used 10 footers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Step 17:   Add insulation to side walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Step 18:   Cut out doors and windows ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Step 19:   Fasten roof stringers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Step 20:   Used pneumatic stapler and glue to add 1/4 ply walls in and out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Step 21:   The ceiling pieces are next ! We used 1 inch wood screws for this bit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Step 22:   Cut and install more insulation in between stringers and taped with heavy duty foil tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 23:   Time to add the bows (1/4 inch lath boards) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Step 24:   Lay poly propylene tarp and install lath strips front ,back and sides . trim off excess ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Step 25:   Stain and Varnish (or paint) your favorite color ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Step 26:   Time to build window frames and door frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Step 27:   Trim over all your seems and around door and windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Step 28:   Add window and door stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Step 29:   Dry fit doors and windows (all built with Kreg Jig) window are 2x2 and door is made from 2x4 and a piece of 4/4 ply. . . . . . . . . . . . . . . . . . . . . . . . . . 28

Step 30:   Finish doors and windows. Cut and mortise for hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Step 31:   Time to take it all back down add window stops, varnish ,dry fit glass. (glass was from seattle stained glass) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Step 32:   Install glass for the last time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Step 33:   Install door windows and hardware !! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Step 34:   Install deck !! exterior is done !!! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Step 35:   Install bed platform and benches I also put some 110 outlets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Step 36:   Install flooring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Step 37:   Install trim over all seems ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Step 38:   Trim trim trim trim ...trim. Add curtains and a bed ! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Step 39:   Finishing touches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Step 40:   ENJOY YOUR WAGONS !! . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Advertisements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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Intro:  Gypsy Wagonhere is the second Gypsy wagon I built along with some friends . I hope you enjoy it.

Step 1: Build your Harbor Freight trailer !

Image Notes1. Harbor Freight trailer

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Image Notes1. 4x8 loads cap 1720 #'s

Image Notes1. fully assembled comes with title too!

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Step 2: Build 4x8 box out of 2x12s

Image Notes1. 2x12's

Step 3: Floor subframe is 2x4s .. you could just slap a 4x8 sheet on this but I was afraid of deflection.

Image Notes1. 2x4 subframe for the floor . You could also just cap it with ply wood but I was worried about deflection .

Step 4: Add 3/4 plywood.

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Image Notes1. 3/4 plywood

Step 5: Screw it all down with exterior grade deck screws.

Image Notes1. time to bolt it to the frame !!

Step 6: I added the ledges first but in retrospect I should have done the gussets first.

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Image Notes1. I added these ledge pieces first but in retrospect I should have put the gussets in first lol!

Step 7: Add you own flare here !

Step 8: Screw and glue all gussets

Image Notes1. add the gussets .

Step 9: You could stop here and have very cool wagon lol!

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Step 10: Time to transfer your drawing from that napkin !

Image Notes1. follow the plan you drew on napkin ! really this could be any shape you canimagine.

Image Notes1. double check your drawings and measurements and hope for the best!

Step 11: Cut out your shape !

Image Notes1. watch out for your fingers !

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Step 12: King pins installed now hang your cut outs on the king pins and screw them down.

Image Notes1. cut the notches for your 2x4 stringers.

Step 13: Front and back walls are hung

Image Notes1. theres a step I missing but you will see the "kingpins " you hang your cutouts on in a bit.

Step 14: Side frame is 2x2s 16s on center.

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Image Notes1. heres those king pins I spoke of.

Image Notes1. 2x2 wall built 16 on center.

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Step 15: Dont forget to cut these notches

Image Notes1. time to cut door and windows.

Step 16: Fit roof stringers I used 10 footers

Image Notes1. dry fitting the 2x4 roof2. dry fitting the inner walls3. the insulation we used inch and a half foam with a tin UV coating.4. A door way !

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Step 17: Add insulation to side walls

Image Notes1. cut to fit.

Step 18: Cut out doors and windows !

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Image Notes1. windows go here.

Step 19: Fasten roof stringers

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Step 20: Used pneumatic stapler and glue to add 1/4 ply walls in and out.

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Step 21: The ceiling pieces are next ! We used 1 inch wood screws for this bit.

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Step 22: Cut and install more insulation in between stringers and taped with heavy duty foil tape

Step 23: Time to add the bows (1/4 inch lath boards)

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 24: Lay poly propylene tarp and install lath strips front ,back and sides . trim off excess !

http://www.instructables.com/id/Gypsy-Wagon-1/

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 25: Stain and Varnish (or paint) your favorite color !

http://www.instructables.com/id/Gypsy-Wagon-1/

http://www.instructables.com/id/Gypsy-Wagon-1/

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 26: Time to build window frames and door frame .

Step 27: Trim over all your seems and around door and windows

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Step 28: Add window and door stops .

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 29: Dry fit doors and windows (all built with Kreg Jig) window are 2x2 and door is made from 2x4 and a piece of4/4 ply.

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 30: Finish doors and windows. Cut and mortise for hardware .

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http://www.instructables.com/id/Gypsy-Wagon-1/

http://www.instructables.com/id/Gypsy-Wagon-1/

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 31: Time to take it all back down add window stops, varnish ,dry fit glass. (glass was from seattle stained glass)

http://www.instructables.com/id/Gypsy-Wagon-1/

http://www.instructables.com/id/Gypsy-Wagon-1/

Step 32: Install glass for the last time.

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Step 33: Install door windows and hardware !!

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Step 34: Install deck !! exterior is done !!!

Step 35: Install bed platform and benches I also put some 110 outlets.

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Step 36: Install flooring

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Step 37: Install trim over all seems !

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Step 38: Trim trim trim trim ...trim. Add curtains and a bed !

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Step 39: Finishing touches

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Step 40: ENJOY YOUR WAGONS !!

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Simpleconversion ofVW T4 caravellesyncro 9 seatsin a campervanbypaolobertoncin

Easy Drapes forTruck CamperShell byazükiBEAN

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Comments

32 comments Add Comment

 jaylabrosse says:  Aug 23, 2014. 12:46 PM  REPLYpart two !

 jaylabrosse says:  Aug 23, 2014. 12:45 PM  REPLYhere's links to the build

 LynxSys says:  Aug 23, 2014. 11:54 AM  REPLYThat's beautiful work! Thanks for including so many detailed pictures of the process. It would be great if there were some more written details too. I'massuming that your trailer isn't meant for use on public roads, given the missing lights and fenders. Can I ask what you're planning to use it for?

 jaylabrosse says:  Aug 23, 2014. 12:41 PM  REPLYHi thank you we use as a bed and breakfast in our back yard ! it came with a title and fenders and lights but we intended to be a cute room to rent. Also beportable .

https://www.airbnb.com/rooms/3200646

https://www.airbnb.com/rooms/762029

 ajohnson119 says:  Aug 23, 2014. 10:57 AM  REPLYThis is amazing work, and a great instructable .. really awesome all round!My woodworking skills are unfortunately on the n00b'ish side.This reminds me (but it's way better than) the Tiny Houses documentary on Netflix.Thank you ... simply inspirational work.

 jaylabrosse says:  Aug 23, 2014. 11:09 AM  REPLYaww thank you thank you ! I love your profile pic we have an English angora bunny that we love !! I never though I could build anything like either but justgotta start and work the problems as they come up . Im sure you can do it !

 jaylabrosse says:  Aug 23, 2014. 10:33 AM  REPLYthank you so much !

 Laylian says:  Aug 23, 2014. 7:58 AM  REPLY?????????????????????????????????????

 jaylabrosse says:  Aug 23, 2014. 10:32 AM  REPLY?????????

 Digitus says:  Aug 23, 2014. 8:15 AM  REPLYWow! Great design & execution. You have done some beautiful work there. I thought I wanted an airstream, but this just oozes charm.

 skiedra says:  Aug 23, 2014. 5:57 AM  REPLYOmgg, the result is awesome.

And it probably took 4 days just to write everything down into an instructable ;)

 netcruiser says:  Aug 23, 2014. 4:51 AM  REPLYGreat work and craftsmanship. You make it look so easy.

 abaltazar1 says:  Aug 23, 2014. 1:24 AM  REPLYI don't have a use for a wagon but I kinda want one.

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 hegure_ryu says:  Aug 22, 2014. 9:20 PM  REPLYThese are great! They remind me of the sheep herder camp trailers around here. You did a great job. My dad always said he wanted one of the old sheepherder trailers, or an old Airstream. These look so fun to make. I would love to try it.

 jaylabrosse says:  Aug 22, 2014. 9:29 PM  REPLYI love sheep header wagons !! I want to build one too ..and live in it ! You should build one it's not hard if you make one piece a day I guarantee you willfinish !

 hegure_ryu says:  Aug 22, 2014. 9:39 PM  REPLYYou really need to enter this into the current Instructables contest: http://www.instructables.com/contest/greatoutdoors...

You really have a great one here.

 tressanemcik says:  Aug 22, 2014. 9:09 PM  REPLYAbout how much did it cost to build all together??

 jaylabrosse says:  Aug 22, 2014. 9:27 PM  REPLYabout 5g honestly have not gone through the receipts im too afraid lol!

 doc.kennedy says:  Aug 22, 2014. 8:30 PM  REPLYGreat craftsmanship and skills. Nice detailed explanations.

 jmwells says:  Aug 22, 2014. 6:37 PM  REPLYGreat looking, tho I would consider window screens. Those no seeums drive me nuts.

 kbp555 says:  Aug 22, 2014. 6:32 PM  REPLYThat is so cool!

 incensedpanther says:  Aug 22, 2014. 5:59 PM  REPLYThese are awesome. I have a couple of questions. 1. Do you know what the total weight is on the one shown in this instructable? 2. How road worthy arethey? 3. What kind of drag is there when you have them on the road? 4. How long do your tires last on average? Is it easy to find replacement tires? 5. Howbadly do cross winds affect them when driving?

 jaylabrosse says:  Aug 22, 2014. 6:17 PM  REPLY1. im not sure but if i had to guess 1000-1200

2. around town and low speed 55 max .

3. has the aerodynamics of a brick .

4. never worn out any . Plenty of tire options.

5. I would imagine not so good in a side wind either but when I did a "tip over test" it took two people to lift it .

 seamster says:  Aug 22, 2014. 5:16 PM  REPLYThis is one of my favorite instructables I've seen in a long time. And I look at A LOT of instructables..

I had a custom teardrop trailer on my to-do list, but it has officially been replaced by "gypsy wagon."

Thank you!

 jaylabrosse says:  Aug 22, 2014. 5:24 PM  REPLYWe built a tear drop ! it was my wife's and she loved it but it felt a bit cramped so we designed these ones . Thank you so much for your kind words !

 Bannockburn says:  Aug 22, 2014. 4:29 PM  REPLYBrilliant, simply brilliant!

http://www.instructables.com/id/Gypsy-Wagon-1/

 jaylabrosse says:  Aug 22, 2014. 4:37 PM  REPLYthank you !

 jessyratfink says:  Aug 22, 2014. 3:47 PM  REPLYAbsolutely gorgeous work! And it looks so good inside, too. :D

 jaylabrosse says:  Aug 22, 2014. 4:37 PM  REPLYyour too kind !

 Pwnie0verload says:  Aug 22, 2014. 2:35 PM  REPLYSo beautiful! And you make it look so easy.

 jaylabrosse says:  Aug 22, 2014. 3:20 PM  REPLYThank you so much !

 jaylabrosse says:  Aug 22, 2014. 10:36 AM  REPLYCut out doors and windows