Building the trailer started with the design – and Burick searched for what he would classify as the perfect design. His search stopped when he came across a 1947 Cabin Car trailer. That was an all-wood design that was crafted by one of the many companies who found the need for their manufacturing capability changed after World War II. They shifted from making aircraft-related products to making things for civilians, and Cabin Car was a small teardrop trailer for civilians.
The trailer’s light weight is a product of how it’s built. Like all RVs, the foundation is the place to start and the one under this foamie is all aluminum. The welded aluminum chassis was put together by another friend and incorporates 13” tires on a solid axle. These are significantly larger than the 8″ tires that the Vespa is shod with.
From there the sidewalls and roof are all cut from 1″-thick block foam, which is a material many RVers may already be familiar with. Many smooth-sided RVs are a product of a welded “cage” with block foam between the ribs.
But the foamie is only block foam, no ribs. Well, not many. More on that later.
The sidewalls and roof are mounted in place and then a layer of canvas is literally glued on top of the foam with “tight bond” glue. At this point you use a warm iron to seal and help dry the layer.
Once the glue dries, the canvas layer becomes rigid and is then painted with waterproof latex paint.
This glue and canvas layer is referred to as “poor man’s fiberglass.” It was around before actual fiberglass, but isn’t tremendously different in concept. In fact, many early trailers used processes similar to this for their skins.
“You would be surprised how much structural rigidity canvas and paint add to the build.”
Thomas Burick has always wanted to build a travel trailer, and now he has. He enjoys pulling it around at speeds up to 40 miles per hour with the collectible 1962 Vespa scooter.
https://www.rvtravel.com/rv-review-vespa-foamie-trailer-1032b/
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