The Ultralight

Warning: This design has not been tested. Use at your own risk.





The Concept

A shortened version of the Modernistic. Pine framing on the outside. Walls are
1/4" moisture resistant luan. Room in galley for stove. Storage under the counter.
Motorcycle battery under counter. 1 light in galley. 1 light in cabin. 1 shelf in cabin.
Goal is under 500#, tongue weight of 75#. 4 X 8 overall.
Mike Schneider 2006
Mike Schneider 2006
Mike Schneider 2006


Mike Schneider 2006
Mike Schneider 2006

Ultralight Profile using x,y coordinates

X, Y
6 3/4, 0
3 1/4, 3
1 5/16, 6
5/16, 9
0, 12
1/4, 15
7/8, 18
2 1/16, 21
3 5/8, 24
5 13/16, 27
8 5/8, 30
12, 33
16 1/4, 36
21 11/16, 39
24, 40 1/8
27, 41 3/8
30, 42 1/2
33, 43 1/2
36, 44 3/8
39, 45 1/8
42, 45 13/16
45, 46 3/8
48, 46 7/8
51, 47 1/4
54, 47 9/16
57, 47 3/4
60, 47 15/16
63, 48
66, 48
69, 47 5/8
72, 47 1/8
75, 46 3/8
78, 45 1/4
81, 43 7/8
84, 42 1/16
87, 39 3/4
90 5/8, 36
92 5/8, 33
94 3/16, 30
95 1/4, 27
95 7/8, 24
96, 21
95 7/8, 18
95 3/8, 15
94 5/8, 12
93 1/2, 9
92, 6
90, 3
87 7/16, 0

Top of door
X, Y
53, 44.45
57, 44.78
60, 44.93
63, 45
66, 44.94
69, 44.64
72, 44.06
75, 43.2
78, 42
81, 40.43


If you dont like x,y coordinates, Andrew has a drawing for you





Andrew Gibbens 2006
Andrew Gibbens 2006



Andrew Gibbens 2006
Andrew Gibbens 2006

Andrew Gibbens 2006 Andrew Gibbens 2006
A view of the cabinets


There are a couple different options for the tongue. This one uses 2x2x1/4 tubing.


Mike Schneider 2006
Mike Schneider 2006
This one uses the channel that comes with the HF 1175# trailer


Regardless of which tongue option you choose, youll need to reinforce your tounge mounting
with pieces of bar stock, as shown in red in this picture.

Mike Schneider 2006
Mike Schneider 2006

The tongue extends beyond the body by 22.



This allows a maxium of 45 articulation with your automobile.

Mike Schneider 2006
Andrew Gibbens 2006
First you need a sturdy construction table.


Layout the profile and use lengths of dowels with the screw offset to allow fine adjustment to
the line of the profile.


Mike Schneider 2006
Mike Schneider 2006
A Closer look at the lengths of dowels with offset screw..

Mike Schneider 2006
Lay up and glue the strips (1/8 strips) NOTE: 1
st
two strips need to be knot free


Lots of clamps are needed..

Mike Schneider 2006
Mike Schneider 2006
You may want to use a clamp like this to hold the strips down to the table


You may want to use a narrower clamping strip than in this picture.



Mike Schneider 2006
This is what it should look like


A suggested method of smoothing the edges.


Mike Schneider 2006
Mike Schneider 2006
In this picture you can see the part of the framing that is going to be above the
door.


In this picture you can see where the hatch begins... in other words, what you are
looking at is the notch for the hatch insulation...

Mike Schneider 2006
Mike Schneider 2006
And in this picture you can see where the hatch ends...(at the clamp)


With the last two layers of lamination on, there was no springback at all.

Next I take the whole mess outside and run it thru the thickness planer!

Mike Schneider 2006


I've now got the swooshdrop on the plywood side, ready for glue up...



But before I can start gluing, I have to pull some wires for the marker lights, and
whatever else I need. Once it's glued, there's no more wire pulling, at least not thru
the sides...


Mike Schneider 2006
Mike Schneider 2006
Cut the groove in the bottom piece for the marker lights and taillights.


Then I glued and clamped that bottom piece down



Mike Schneider 2006
Mike Schneider 2006
Axle support assembly. The vertical piece in the back gets cut off



Mike Schneider 2006