Building Teardrop Camper Doors: A Comprehensive Guide

how to make teardrop camper doors

Teardrop trailers have gained popularity in recent years due to their small size, light weight, and ease of towing. They are typically low to the ground, have a short door, and provide the essentials for camping. Building your own teardrop trailer is a great way to customize your camping experience, but it can be challenging to ensure your doors seal properly. This introduction will cover the basics of how to make teardrop camper doors, including the materials you'll need, the steps to follow, and considerations for sealing your doors to protect against water damage.

Characteristics of Teardrop Camper Doors

Characteristics Values
Door Shape Square, straight edge on the hinge side, long side arch, simple arched top, rounded corners, or custom
Hinge Styles Regular house-style, piano, gate
Door Design Square with a home-style door jam, seals, and door knob, or side arch style with piano hinge and seal
Door Seal Inside seal, outside seal, or a combination of both
Materials Wood, plywood, aluminium, polyurethane glue, moulding, screws, weatherstrip glue, etc.
Size Teardrop trailers are typically 8 feet long with 4-foot-high side walls, resulting in a short door

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Door shape and hinge style

When it comes to making teardrop camper doors, there are several considerations to keep in mind regarding the door shape and hinge style.

Door Shape

The shape of the door will influence the type of hinge you can use and the effectiveness of the door seal. Some common door shapes for teardrop trailers include:

  • Square doors: These are straightforward to construct, similar to a typical house door. However, they may not be as stylish as other options.
  • Side arch style: This style features a straight edge on the hinge side and a long arch on the opposite side. It is often paired with a piano hinge and a seal placed in the pinch area behind the hinge.
  • Rounded corners: While aesthetically pleasing, this shape can be more complex due to the "pitch" motion created by the seal surface behind the hinge. This motion can push the seal out of position and make it less effective.

Hinge Styles

There are three main types of hinges used for teardrop trailers:

  • Regular house-style hinges: These hinges require a door jam constructed deep enough to accommodate them. They are standard and familiar, but may not offer as much customisation as other options.
  • Piano hinges: Piano hinges are commonly used for teardrop trailers. It is important to select one with a galvanised pin to prevent rust. Nylon piano hinges are also available, but they do not have a pin.
  • Gate hinges: Gate hinges can be easily attached by bolting them on, and they offer the advantage of having an offset pivot point. However, it is crucial to find gate hinges with nylon bushings, as those without can be too loose to hold the door securely.

When choosing the hinge style, consider the shape of your door and the desired placement of the door seal. The hinge should complement the door shape and allow for effective sealing.

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Sealing the door

Choose the Seal Type:

You have two main options: an inside seal or an outside seal. Each has its advantages and drawbacks.

Inside Seal:

This method involves adding moulding around the inside of the door opening and placing the seal on this moulding, facing outwards. The advantage is that it allows the exterior of the door to be completely flush with the sidewall, and the path for water to reach the seal is inherently more challenging. However, the downside is that the interior moulding takes up valuable space in the already narrow cabin, and any imperfections in the door opening cut will be visible and may require sanding.

Outside Seal:

This method involves adding moulding around the outside of the door itself and placing the seal on the moulding, facing inwards. The advantage is that it hides any imperfections in the door opening cut and maximises interior cabin space. However, the seal will be directly exposed to driving rain, so you'll need to add a barrier moulding around the outside of the door to block the rain. Additionally, unless you have a curve-free hinge side with square corners, you'll be limited to using gate hinges instead of piano or house door hinges.

Door Shape and Hinge Style:

The shape of your door and the type of hinge you choose will impact the effectiveness of your door seal. A square door allows for a more straightforward construction, similar to a standard house door, but may not be as stylish. On the other hand, arched or rounded door designs can increase complexity, especially when considering the seal surface and the type of hinge required.

There are three common hinge styles for teardrop trailers: regular house-style hinges, piano hinges, and gate hinges. House-style hinges require a deeper door jam but are familiar and straightforward. Piano hinges are common for teardrop trailers, but ensure you choose one with a galvanised pin to prevent rust. Gate hinges are versatile and can be attached without a custom jam, but they must have nylon bushings to hold the door securely.

Seal Placement:

When placing the seal, consider how rain will behave on the trailer. Driving at high speeds can create hurricane-force wind conditions, and no seals are designed to withstand such extreme conditions. Design the openings to be flush with the sides, and keep seals out of the direct flow of water as much as possible. You may need to add a perimeter "guard" or deflector on the body adjacent to the door to divert water away from the seal.

Seal Maintenance:

Finally, remember that a homemade teardrop camper is still susceptible to some water intrusion. Treat it like a tent and ensure you clean, dry, and ventilate it properly after each camping trip. A few drops of water here and there are normal, so don't stress over making the doors absolutely watertight. Focus on effective sealing techniques and regular maintenance to ensure a comfortable camping experience.

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Using moulding to seal the door

When making a teardrop camper door, one of the most important considerations is how to seal it to prevent water intrusion. This can be done by adding moulding to the inside or outside of the door opening.

Inside Seal

One method is to add moulding around the inside of the door opening, on the body, and place the seal on this moulding facing outwards. This approach has the advantage of allowing the outside of the door to be completely flush with the sidewall, making it more difficult for water to reach the seal. However, the downside is that the interior moulding reduces the already narrow cabin space, and any imperfections in the door opening cut may be visible and require sanding.

Outside Seal

Another option is to add moulding around the outside of the door itself and place the seal on this moulding facing inwards. This method hides any imperfections in the door opening cut and maximises interior cabin space. However, the seal will be directly exposed to driving rain, so additional moulding is needed around the outside of the door on the body to block the water. This method also restricts the type of hinge that can be used unless the hinge side of the door has square corners.

Hinge Styles

There are three common hinge styles for teardrop trailer doors: regular house-style hinges, piano hinges, and gate hinges. Regular house-style hinges require a deep door jam and are less customisable. Piano hinges are commonly used for teardrop trailers, but it is important to ensure they have a galvanised pin to prevent rust. Gate hinges are easy to attach and offer more flexibility with the pivot point, but it is important to find ones with nylon bushings to ensure the door closes precisely.

Door Design Considerations

The shape of the door will impact the type of hinge used and the sealing method. Square doors can be constructed like a typical house door, but they may lack style. Adding a perimeter moulding around the outside of a square door and arching it can enhance the profile. One popular style is the side arch door, which uses a piano hinge on the straight side and a seal in the pinch area behind the hinge. More complex door styles, such as those with rounded corners, can be more challenging to seal effectively.

Managing Rain

Understanding how rain behaves on the trailer is crucial. Rain will travel along the body surface, and at high speeds, it can create hurricane-force wind conditions. Seals should be designed to stay out of the mainstream of water flow as much as possible. This may involve adding a perimeter "guard" on the body adjacent to the door or a deflector over the top and front of the door. It is also important to keep things in perspective—a homemade teardrop trailer is one step up from tent camping, so some moisture may be expected.

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The pros and cons of an inside seal

When making a teardrop camper door, you need to consider how you are going to seal the door to prevent water intrusion. The two main options are an inside seal or an outside seal.

An inside seal is created by adding moulding around the inside of the door opening and placing the seal on this moulding facing out. This has the advantage of allowing the outside of the door to be completely flush with the sidewall. The path water would have to take to reach the seal is difficult, reducing the chances of water intrusion. However, there are also downsides to an inside seal. The interior moulding takes up valuable space in the already narrow cabin, and any imperfections in the door opening cut are visible and may need to be sanded.

On the other hand, an outside seal involves adding moulding around the outside of the door and placing the seal on this moulding facing in. This method hides any imperfections in the door opening cut and maximises interior cabin space. However, the seal is directly exposed to driving rain, and you will need to put a barrier moulding on the body of the door to block the rain. Additionally, unless you have a curve-free hinge side on the door, you will be limited to using gate hinges instead of piano or house door hinges.

Ultimately, both methods of sealing have their pros and cons, and the choice depends on the specific design and requirements of your teardrop camper.

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The pros and cons of an outside seal

When making teardrop camper doors, one of the most important considerations is the door seal configuration. An outside seal has several advantages and disadvantages that should be weighed carefully before making a decision.

One of the main benefits of an outside seal is that it hides any imperfections in the door opening cut. This can be especially useful if you are not confident in your cutting skills or if you want to achieve a neat and flawless finish. In addition, an outside seal preserves the interior cabin space, ensuring that there are no protrusions that you might accidentally bump into during the night. This is particularly advantageous in a teardrop camper, where space is already limited.

However, one of the significant drawbacks of an outside seal is its exposure to the elements. The seal will be directly exposed to driving rain, requiring the addition of a barrier moulding around the outside of the door to protect it. This can be cumbersome and may detract from the overall aesthetics of the camper. Moreover, the type of hinge you can use may be limited. An outside seal typically necessitates the use of gate hinges, which may not be as readily available or aesthetically pleasing as other hinge types.

Another factor to consider is the shape of the door. An outside seal is more suitable for doors with square corners and straight hinge sides. If your door has rounded corners or a curved hinge side, the seal may not function optimally. The closing motion of the door can cause the seal to traverse sideways, potentially pushing it out of position and compromising its effectiveness.

In conclusion, when deciding whether to use an outside seal for your teardrop camper doors, it is essential to contemplate the advantages and disadvantages. While an outside seal can provide a neat finish and preserve interior space, it may also require additional protection from the weather and limit your hinge options. The shape of your door and the potential exposure to rain are also critical factors in making this decision.

Frequently asked questions

First, you need to decide on a door shape. There are many variations, including square, straight-edged, or arched. The shape you choose will impact the type of hinge you use and your sealing options.

There are two main options for sealing the door: an inside seal or an outside seal. An inside seal involves adding moulding around the inside of the door opening and placing the seal on this moulding, facing out. This option allows the exterior of the door to be flush with the sidewall, but it takes up some interior cabin space. An outside seal involves adding moulding to the door itself and placing the seal on the moulding, facing in. This option hides imperfections in the door opening cut but will expose the seal to driving rain, so additional measures are needed to protect it.

There are three common hinge styles used for teardrop trailers: regular house-style hinges, piano hinges, and gate hinges. House-style hinges require a deeper door jam, while piano hinges are commonly used but typically have a plain steel pin that will rust. Gate hinges are easy to attach and allow for offset pivot points but must include nylon bushings to hold the door in place.

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