Edmonton’s dry climate made working with paint much easier, but the cold winter made many things much more challenging. Not wanting to wait for warmer weather to get started I took every drop cloth, tarp, towel and piled them on the shell. Then running an electric heater inside I could make in more bearable to work (still couldn’t get it above 0).
With this I started installing the insulation. I used pl400 to glue it up, as it could handle the cold temperatures (I like contact cement better, but it had to warm up to make that an option).
The sheet is over the door attempting to hold in the heat, while the door is holding up the insulation while it dries.
A little more still needs to be glued, but it is taking shape.
I started leaving the windows cover to keep it warmer, would cut them out later.
With the insulation up I started to work on building the furniture that was missing. If I could do it again I would make it much liter, but having no idea how to attack this it turned well. With everything curved, I leveled up the trailer and built everything with a square or level from the floor.
Test fitting the cabinet floor (and the table),
Test fitting the table
Sides are on the cabinet
I had seen some other Bolers had extended the counter to the front of the trailer, and liked that option, so I took it a step further and made the bunk the same height as the counter. This not only gave me a counter extension, but an option for a wrap around counter. The other piece could have a railing added to make a bunk, or swing down to make a couch.
Counter piece cut and placed in. It will go to the front of the trailer.
The bunk / counter piece cut and placed in for fitting.
A shot of the cabinet and bunk progress from the inside of the trailer.
Everything was designed with measurements taken from the trailer at the belly band height. I did not expect the curves to add the challenges they did.
Measurements taken at the dinette floor height.
Measurements are approximately the middle of the Boler Trailer. Curves near to top are estimated.
Top bunk / counter plan
Cabinet and Counter Plan
Kitchen Cabinet and Counter Plan
Plywood plan for this project.
I picked up some LED lights for the trailer, a piano hinge for the couch and table, and other hardware for the bunks.
I picked up a leg from ikea to support the dinette table.
Table leg from Ikea
The full sized dinette table seemed like a little too much, so I borrowed the idea of folding it in half as I have seen on other trailers on the internet.
Little E was building an ice cream truck, you can see branches and other random things he’s collected to build it.
The table support and start of the bike rack.
The bed is cut, just need to make it into a table
E has been spending lots of time working on the Trailer with me (and you can see the couch cut in the background)
Simple plumbing, it drains into a bucket.
The cut worked!
The Closet door
Still need to be sanded, and finished.
I started on the closet shelves.
Shelves cut to fit.
A cut out allows access below the bottom shelf
Prepping the Pine for Stain
Filling the screw holes
Cleaning up the fiberglass furniture.
New wood pieces cut for all of the fiberglass furniture.
With the temperatures warming up, I got out the contact cement and glued the uv stabilized outdoor carpet up. This should help insulate, keep it dark in the mornings, and hide the seams so there is no need for seam tape.
I did want a wipeable surface on the walls to deal with any spills on the table. My wife also picked out the flooring, which looked great.
Floor cut and Carpet up!!
Starting the Carpet
All the furniture needed to be cleaned, filled and painted. Any cracks where fiberglassed. Underneath the paint I found grass, dirt and a wasps nest.
Trimmed up the side (top in picture) of the closet.
Adding wood to the fiberglass benches.
Wood drying after another coat.
The door had been damaged at some time, the first attempt to fix it had failed, so I attacked it again, with the ne skills from this project it worked well this time.
After pulling the clamps off. Inside.
After trimming the door up. Outside.
Fixing holes, chips and other damage.
Patching cracks with fiberglass, then finishing with filler.
I squared off the corners of the benches to make the bed bigger.
Dinette Extension progress
For the cabinets I found a youtube video, and used this to make the cabinets, bunk rails, mirrored door and it worked great.
Top Bunk Railing
Doors to hide toilette
E ran ahead to get ready to paint.
He worked at painting for 3 hours, and was ready to go in at that.
Installed some molding and the front bench to hold the floor in place.
The rest of the furniture goes in.
I like the wood trim and floor together.
I also used contact cement to glue on the countertop.
Marking out the counter top to be cut
Letting the Glue Dry
The boys hard at work,
The bottom shelf center lifts out so things can be stored below.
Bottom Shelf of the Closet with insert.
You have to put an Ikea bin in the closet to be a trendy Boler own it seems.
Installed couch back on the hinge.
Couch flipped up to make a counter top or top bunk.
These hold the top bunk up, and easily support someone well over 200 lbs (as I got up there and tested it).
Hardware to support the bunk / counter
Hardware to support bunk bed / counter
Glued together the light holder for above the counter.
Assembled table support, so the table can be used as a half table. This is it extended
Table support closed
Installed Closet Door
Inside of closet
Light for above sink and counter.
I added a computer fan to the vent, much more affordable that the ones you buy, uses less energy and works great.
Computer fan installed in the roof vent.
It was time to finish repairing the outside. I went through a lot more Bondo than I ever thought I would have.
Bondo and holes cut for propane cooler vents
Windows all taped up
Vent holes from the inside.
Being cheap I installed a propane cooler. It was a bad option, I ended up selling it and getting an old propane fridge that works a 1000 times better. Got tired of throwing out spoiled food as the cooler would stop working.
Cooler set in to test fit.
New Tongue Jack
LED Light on Wood Mount
White Roof Vent Trim Ring
I used old foam sleeping mats for the boys and a $12 air mattress for use to camp the first year.
Boys trying out the beds
Using a scrap piece of metal I made a bracket to make the bank rail solid and removable.
Starting to make the bunk hardware
The finished piece, just need paint.
With the squared up corners on the benches, the bed was bigger, and didn’t need an extension that needed to be stored elsewhere.
Table set down to make the bed extension.
Bed extension Hardware
Extension pulled out
The parts I used to attach the wires.
Wires tied up
LED marker Lights
Switches tucked away
Adding more moldings
I went with a magnetic screen door. It is great as no hands are needed to open it when loading and unloading the trailer and the boys never leave it open.
Molding to attach drip cap for the door to and mount the screen door.
Added Latches to Cabinet Doors
New Bike Rack
12 volt vacuum
CO2 and Smoke Detector
I also installed a wrap around curtain rod. Liked the look.
Curtain rod starts at the closet.
Curtain rod was installed from the kitchen to the first bend at the front of the trailer.
Curtain rod over Counter to add storage.
It fits out further if we decide we need it.
One wheel had lug nuts, the other was bolted on.
Wheel cleaned up
Rim Painted Brown
Wheel on the trailer is painted, beside is the one still needing paint
Full sized screen
Screen cut to size
Glued the fabric together
Screen back together and ready to be installed
Screen from the inside
Top of door
Finishing pieces for the bottom
Added the last hardware to the bunk railing.
I experimented with different ways to create small decals, settling on a knife and colored duct tape to make the flames.
Found using a stickers makes a nice template for spray painting.
Finishing up the table hardware.
Temporary Air mattress for this summer
Locked the bunks in place
Boler Logo Template
Cooler is Clamped and solid.
Green Boler Rebuild 4