Building A Gypsy Wagon
Building A Gypsy Wagon
Building A Gypsy Wagon
Table of Contents
Step 4: Walls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Related Instructables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Comments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Author:paleotool paleotool
Naturalist, scientist, builder, and maker.
Most of the actual work was performed with a table saw, band saw, drill, and a slew of hand tools as I found time around my day job. Although I don't really consider it
"done", it is complete enough to use and is currently on the road.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Step 2: Trailer Conversion
I found a sturdy little cargo trailer with a heavy duty frame and tongue. The first step was to cut off the box with a reciprocating saw and grinder. I intended to save the
wiring harness and lights but they proved to be outdated and fairly ratty.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Image Notes Image Notes
1. A folding trestle work table I built as a precursor as I no longer have a real 1. The pipe clamp kept tension across the band board during movement.
workshop. Everything is going mobile.
2. The ledges and side boards are premium yellow pine. Brackets are poplar.
Step 4: Walls
The walls are built like a box, not like modern stick framing. All are tongue and groove pine, the front and rear being 3/4" thick, the sides 1/4". This is why the sides have
hardwood strengthening battens (1") run vertically inside and out on 1' centers. Corner posts are made from 1 1/4" pine stock. Outside corners are oak. Upright bracing
around the door inside and out from poplar. Upright bracing on front wall is oak. Sub-floor is 1" salvaged plywood.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Step 5: Internal Structure and Roof
The bed structure ties the walls together and stiffens the entire structure. Without this, I would have to find some other way to strengthen the walls. The roof is plywood,
screwed to poplar purlins. Outer and inner tops of walls are stiffened with oak band boards.
Image Notes
1. Purlins are poplar, 1 1/2" x 3/4". The roof is screwed to these as well as the end
walls.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Step 6: Table, Window, and Door
The table is modeled after those in old British wagons. The window was made as a separate unit and then attached whole to the wagon body. It is oak and pine. The
door is modeled after some sheep wagon styles from the western U.S. It is a "Dutch door" with a functional casement window and a wash pan holder. Not quite finished
in the photo below but nearly there.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Step 7: A Trial Run and Some Finishing Touches
We took her on a 500 mile journey into the desert to test her out and figure out some interior layout issues. We got a base coat of oil paint on most of the body by the end
of the week. After we returned, we added an oak floor, finished the table, and added a lot of homey touches. There ample storage under the beds, but I intend to add
more outside.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Image Notes
1. Heavy weight waterproof tarp canvas stretched over 30# roofing felt.
2. New lights and wiring harness.
Image Notes
1. The lower bed is full width and has a large storage locker beneath. The curtains
provide privacy and control the temperature a bit.
2. The bed rail on the expandable section is oak to provide stiffness.
3. Table is complete with an oak front and brass handle.
4. The upper bed has two smaller storage lockers beneath.
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Image Notes
1. Leg removes and is stored in a rack on either wall.
2. Floor finished in 3/4" red oak planks.
3. Area under stove is protected by slate tiles.
4. Small shelf runs entire length of wagon.
Roof: Although I didn't photograph this step, the roof was ultimately covered in a low profile steel that was epoxy coated in the factory. It is a light color to keep some of
the radiant heat out and seems to work well. It is screwed through the roof into the purlins.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Image Notes Image Notes
1. Roll down cover to hide shelves. 1. Roman shade stiffened with bamboo rods.
2. Bench storage.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Step 9: The Stove
With autumn here I felt it was time to deal with the dreaded stove. I made a hearth area in the corner, tiled the riser with slate, covered the walls with 14 gauge flashing,
covered that with fire shield board, inserted a wall thimble, and placed the pipe and stove in the wagon. In case of rough driving conditions, the stove is screwed to the
deck, and two large eye screws attach it to the back wall. It is unlikely to move in anying short of a rollover. The stove is from Four Dog Stoves and is probably too big
for this space. Its what I had though.
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Image Notes
1. "Pan Box" for volatiles and smudgy stuff.
2. Side boxes for jacks, tools, etc.
3. New spare tire holder (steel), mounted to a heavy oak reinforced post.
4. Heavy duty trailer tires.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Step 11: Living Space
Only with time will the wagon really take on a personality as it get lived in and things are arranged "just so". Like a ship or any small living space, a good deal of thought
needs to go into every little detail, especially when it comes to storage. I think it will help me minimize and is now my real "escape pod", whether its to get to the
mountains or beach, or to just someday hit the road. Here is a three photo pan to give a feel for the space.
There are a few more photos of the rig and other stuff on my weblog at http://paleotool.wordpress.com/ under "projects" and "vardo". It will be updated as it is continually
improved.
Image Notes
1. View to Port Side
Image Notes
1. View to rear from bed.
http://www.instructables.com/id/Building-a-Gypsy-Wagon/
Image Notes
1. Clamp closed.
Image Notes
1. Improved shelving for storage of spices, soap, oil, tea, etc.
2. Safety bolts to hold the stove in case of collision or extreme driving
conditions.
3. Lantern is held fast by a clamp to its base. See other photos of its
construction.
Image Notes
1. Clamp open.
2. Messy workbench.
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Comments
50 comments Add Comment view all 78 comments
Im in the SCA http://www.eastkingdom.org/index.html and Im tired of tents lol all the canvas and poles and it always rains lol. Just big enough for a
queen sized mattress and a little cabinet to put a porta pottie in and room for some gypsy garb. Can stick the other junk down below when I get to the
camp site. I want to s fald the mattress liek a futon to use it as a couch so maybe 4 people can hide out inside if its raining or something.
Can you send a link to the metal roofing material you used? Its makin my brain think up some ideas lol.
thanks
deryk
Google' Verdos' and see the extensive art work done on them.
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paleotool says: Feb 20, 2011. 4:40 PM REPLY
Dr Bill,
I think its that is a fairly strange thing to say. Just returning from instructing a survival gathering where I sometimes teach. I was just out on BLM
and Forest Service Land that you and I both own together. Had it all been private land I couldn't have been there. I don't know much about
politics or the words you are using here as I am a fairly off-grid out of touch survivalist but I don't quite get what you are saying. I couldn't get out
and hunt in the forest either if it was all privatized. I think our downfall was ending public spaces in most of the country. Its hard to be a hunter or
gatherer these days. Ayway, I hope my woodworking project doesn't become a political fight.
Thanks,
the Paleotool
I am dreaming of making a similar creature that can be jacked up off the trailer for storage so that I can still use the trailer for utility purposes.
Question: "Hello Paleotool, I love your Wagon. I would like to build something similar but I have a few question on your design . First off , How long ago did
you complete the work ? Reason I ask is ...How well is it holding up? Not that I doubt the construction its just a rigid body on a solid frame. Probably gets
jarred pretty good on the highway ? Whats the weight ? Well, I had more questions but they have slipped my mind for now. I ask you more again soon if you
don't mind ?
-Funtickets"
Reply:"Mr Funtickets
Although its still not done, it hit the road with its first big trip last February. It was essentially a finished shell without all the amenities. I took it on an off-road
shakedown cruise for about a mile and a half of extreme driving. I then checked and tightened all the bolts and checked for movement. All was square,
plumb, and solid. If you read comments and look at the design you will find that all hardpoints are reinforced or built from oak. This includes corners, most
bracing, and wall stiffeners. Other points critical to the structure are generally poplar or oak and the body is essentially a balloon of pine wrapped around this.
She has about 6,000 miles on her now, and some very extreme off-road with no apparent damage or structural change. She has been out for the weekend
as recently as a week ago. The only issue I have had is with the thin pine on the side walls in the extreme desert dryness is some unexpected shrinkage. It is
purely cosmetic but still quite annoying (but fixed now).
I think of the structure like a wooden ship. There should be allowance for movement, but not much and everything should interlock. Even the interior
furnishings such as the bed, storage bins, kitchen storage, and shelves are contributing elements to the overall structure and were designed that way from
the beginning. My secret: before becoming a lazy academic (and for some time in graduate school) I worked as a custom house framer, a general carpenter,
and rigger. While not exactly an engineering degree, I have a lot of experience building large things such as houses and small boats.
Finally, the magic question; what does it weigh? I have not stuck it on a scale yet but I think it weighs about 1500 pounds fully loaded. This is based on a wild
estimate of lumber weight, the original trailer weight, and what it feels like behind the truck (I can only really feel it keenly on hills). The build would have been
much simpler and taken less time to plan if weight was no concern but I put a lot of effort into keeping the weight down. The tricky bit is to keep from filling it
up with heavy stuff.
Paleotool"
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paleotool says: Jan 20, 2011. 10:04 AM REPLY
Those are just standard car jacks. They stow in one of the underside boxes. I have four if I want to be very solid and finicky but I often just use two in the
rear and the tongue jack.
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sravet says: Oct 31, 2010. 7:47 PM REPLY
Do you cook on the stove, or is it just for heat?
(This was a great instructable. I'm sure we'd all like to see more of your work!)
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Rainh2o says: Oct 7, 2010. 7:41 PM REPLY
This is cool!
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