Building Teardrop Camper Walls: A Step-By-Step Guide

how to make teardrop camper walls

Teardrop trailers have become increasingly popular in recent years due to their compact size, light weight, and ease of towing. Building the walls of a teardrop camper is a highly customizable process that can be done in several ways. The most common methods involve using wooden frames, plywood, and insulation to create walls that are functional, lightweight, and aesthetically pleasing. The walls can be insulated and wired internally, and various types of plywood can be used depending on the desired finish. The shape of the walls can also vary, with some curving outwards beyond the front of the bed and others attaching perpendicularly to it.

Characteristics Values
Wall material Plywood, solid wood, Styrofoam, aluminium
Wall thickness 1/2", 3/4", 1", 1-1/2", 2"
Insulation Yes/No
Wall construction Solid piece of wood, sandwich method, laminated bow, plywood framework
Wiring Inside the wall
Varnish Marine-grade urethane varnish
Hinge styles Regular house style, piano, gate
Door shape Square, side arch style, simple arched top, rounded corners
Wall height 4 feet

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Wall insulation

There are several ways to insulate your teardrop camper walls. One of the simplest methods is to use a solid piece of wood. This can be a single sheet of plywood, which is a popular choice for commercial teardrop trailers. Alternatively, you can use marine-grade plywood, AC or BC-rated plywood, or a solid birch or other hardwood plywood. Baltic birch is a good choice for a smooth finish and stability during cutting.

If you plan to paint or finish the exterior with another covering, AC or BC-rated plywood is a cost-effective option. For a lightweight and flexible approach, you can create a frame for your wall using a wall template and plywood, then remove excess material. This method allows you to run wires inside the wall, out of sight, and insulate the walls effectively.

Another option is to make a composite wall structure with thin plywood for the outer and inner layers, and a Styrofoam centre for insulation. This method is commonly used for motorhome and travel trailer walls. Ensure that you use a wood core in areas where things need to be attached, such as where the wall partition attaches.

When insulating your walls, you can use either fibreglass batts or Styrofoam sheets. Styrofoam is easier to work with, but you will need to cut channels for any wiring. Fibreglass batts are more forgiving and can be compressed to accommodate wiring and other elements.

For wall thickness, most teardrop camper walls range from 1/2" to 2" thick. The thickness will depend on your chosen build method and desired level of insulation. Some builders recommend using thinner plywood, such as 1/4" for the outer walls and roof, to reduce weight while still providing sufficient insulation.

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Wall thickness

The thickness of the walls in your teardrop camper will depend on the materials you choose to use and the method of construction.

If you opt for a solid piece of wood, you can select from a variety of plywood types, including marine-grade plywood, AC or BC-rated plywood, or solid birch or other hardwood plywood. The thickness of these plywood sheets can vary, with some walls made from a single piece of 1/2" thick plywood, while others use 3/4" thick plywood.

Another construction method involves creating a sandwich structure, where the wall thickness includes an inner framing, insulation, and outer and inner plywood layers. For example, one builder used a combination of 1x4 and 1x2 wood with biscuits and pocket screws to hold the inner framing together, resulting in walls that were slightly overbuilt compared to others. The inner and outer layers can be made from different types of plywood, such as Baltic birch, AC or BC-rated plywood, or luan plywood, with thicknesses ranging from 1/8" to 5/16" commonly used.

Insulation is an important consideration for the walls of your teardrop camper. Common types of insulation include foam board, Styrofoam, or fiberglass batts. The thickness of the insulation can vary, but it is often mentioned in the range of 1/2" to 1" or slightly more.

When deciding on the thickness of your walls, it is essential to keep the overall weight of the trailer in mind. Thicker walls and heavier materials can add considerable weight to the trailer, making it more challenging to tow. Additionally, thicker walls will reduce the internal space available in your teardrop camper.

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Wall construction

There are several ways to construct the walls of your teardrop camper. The simplest way is to use a solid piece of wood. Depending on how you want to finish the walls inside and out, you can select a marine grade of plywood, AC or BC-rated plywood, or a solid birch or other hardwood plywood. Baltic birch is a popular choice due to its stability, smoothness, and flatness, making it easy to cut and resulting in a good-looking product.

Another method is to create a "sandwich" structure, similar to the floor construction. This involves making an inner framing for your wall using a wall template and 3/4" plywood, then removing the excess material to lighten the walls. You can also add foam insulation to the frame before finishing the walls with plywood or another suitable material.

If you choose to go with the more time-consuming but flexible method, you can run wires inside the walls, completely hidden from view, and insulate the walls to make them lighter.

When designing your walls, it's important to keep the weight down so that your car can easily pull the trailer. One way to achieve this is by creating empty spaces within the wall structure to lower the overall weight. You can also use two layers of plywood with insulation in between for added strength and insulation.

Another option is to make a composite wall structure using thin plywood for the outer and inner skins, with a Styrofoam center core for insulation. This method is commonly used for motorhome and travel trailer walls. However, ensure that you have a wood core in areas where things need to be attached, such as where the wall partition attaches.

For a unique look, you can create a curved laminate wall. Soak thin plywood strips in water to make them pliable, then layer them onto a mold, coating each strip with glue. Clamp each piece and stagger the seams until you reach the desired thickness. Once dry, remove the clamps and mold, and your curved laminate piece is ready to be used as part of your wall structure.

Finally, remember to plan ahead for any attachments you want to add to the trailer later, such as fenders, and ensure that your walls are well-sealed to protect them from water damage.

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Wall materials

The walls of your teardrop camper can be constructed in several ways, depending on your preferences for weight, cost, and complexity. The simplest method is to use a solid piece of wood, such as a sheet of plywood. However, this approach may result in heavier walls.

If you prioritise a lighter and more flexible build, you can opt for a more intricate method that involves creating a wooden frame and running wires and insulation inside the walls. This approach allows for hidden wiring and provides the option to use various types of plywood or hardwood for the inner and outer surfaces. For example, Baltic birch plywood is known for its smooth finish and stability during cutting. You can also consider using a "sandwich method," which involves making a wooden frame, adding foam insulation, and finishing with plywood or hardwood.

Another option is to create a composite wall structure using thin plywood for the outer and inner layers, with a Styrofoam centre for insulation. This method is commonly used in motorhomes and travel trailers. If you go with this approach, ensure that you incorporate a wooden core in areas where things need to be attached, such as where the wall partition attaches.

When selecting plywood, consider using pressure-treated plywood for the floor to prevent water damage. For the walls, you can use marine-grade plywood, AC or BC-rated plywood, or solid birch or other hardwood plywood. If you plan to paint or apply an additional finish to the exterior, AC or BC-rated plywood is a cost-effective option.

To further reduce weight, you can create a laminated bow with 2" x 2" framing or cut the framework out of plywood. The laminated bow method is stronger and lighter but more challenging to execute. Alternatively, you can cut the side frames from a single sheet of plywood to simplify the construction and lower costs.

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Wall finishing

The walls of your teardrop camper can be finished in a number of ways, depending on your preferences and budget. Here are some options for wall finishing:

Materials

For the outer walls, you can choose between a thin layer of plywood or aluminum. Both options are popular, but plywood exteriors often include contrasting wood strips to create a unique look. If you choose plywood, make sure to use marine-grade plywood or AC or BC-rated plywood. Baltic birch is a great option for a smooth surface and an attractive finish. It is also stable and cuts well. Many commercial teardrop trailers use solid birch walls with a varnish finish.

For the inner walls, you can use a variety of materials such as marine-grade plywood, AC or BC-rated plywood, solid birch, or other hardwood plywood. If you plan to paint or finish the inner walls, AC or BC-rated plywood is a cost-effective option.

Insulation

Insulating your teardrop camper walls is important for comfort and energy efficiency. There are a few options for insulation:

  • Fiberglass batts: These are easy to work with and can be compressed to make allowances for wiring and other obstructions.
  • Styrofoam sheets: While Styrofoam is easier to install, you will need to cut channels into it for your wiring.
  • Foam insulation: This option is commonly used and provides effective insulation for the walls.

Wiring

Before finishing the walls, it is crucial to run any necessary wiring for lighting, devices, and other amenities. This includes wiring for interior and exterior lights, speaker stands, a water pump (if needed), and a battery to power everything.

Skinning

The process of "skinning" involves attaching the outer layer of material to the walls. For plywood walls, use PL premium adhesive and place weights on the plywood until it dries. You can also use a nail gun to add staples for extra security.

Painting and Varnishing

Once your walls are constructed and insulated, you may want to apply a finish such as paint, stain, or varnish. If you choose to use plywood, coat the walls with several heavy coats of urethane varnish to protect them from moisture and rotting. You can also apply any stain, varnish, or paint to customize the look of your trailer and even match it to your car.

Sealing

Finally, make sure to seal all seams and holes with silicone caulk to protect your teardrop camper from water damage. Filling any gaps will ensure that your trailer remains dry and comfortable during your camping adventures.

Frequently asked questions

You can use a solid piece of wood, or marine-grade plywood, AC or BC-rated plywood, or a solid birch or other hardwood plywood. You can also use a composite wall structure, with thin plywood for the outer and inner skins and a Styrofoam centre core for insulation.

The thickness of the walls depends on your chosen build method. They can be anywhere from 1/2" to 2" thick.

Polyurethane glue is ideal for building a teardrop camper as it fills gaps and is extremely strong.

There are two basic ways of building walls for a teardrop trailer: making a laminated bow with 2"x 2" framing, or cutting the framework out of plywood. The laminated bow is stronger and lighter but harder to make, whereas the plywood frame is quicker and simpler.

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