Tag Archives: custom

photo showing Marilyn Cooking with the new galley table

New Countertop for the Galley

Jim, July 24:

Trailer kitchen in the living room.

Trailer kitchen in the living room.

The Problem

Over the last several trips, I realized we were spending a lot of time setting up and striking each campsite. The lack of storage was corrected with the tongue box, but the Timber Creek Camp Kitchen took too long to set up. We needed another surface for the stove. I began to think about a counter that would hang on the galley edge.

There were several criteria. It had to attach with little modification and compliment the style of the teardrop. It had to store easily and be strong enough to support a two-burner stove with pans and skillets. And of course, it had to set up quickly. The raised lip at the back end of the galley could be used as an attachment point, but without legs supporting the other end because of the trip hazard. The best solution was to cantilever the counter with support from the underside of the trailer. Time’s a wastin’!

The Build

photo of Initial mockup

Initial mockup

I cut a 21-inch by 26-inch piece of birch plywood. This was the largest surface that would mount in the hatch opening without interfering with the galley storage.  It was long enough to support our camp stove with a propane bottle. Next, I cut 9-inch pieces of 3/4-inch steel strap and bent one end to form an “L”. These fit into the gap between the galley countertop and hatch lid while attaching to the plywood. Using a couple of clamps, I mocked up the proof of concept. Success!

photo of Trial fit of support pattern

Trial fit of support pattern

Now for the cantilever supports. I wanted a design that would fit our teardrop. I drew a shape on a scrap of masonite and cut it with a saber saw. A trial fit with the table mockup looked promising, but I would have to match the curving shape of the trailer exactly. Several rounds of cut and fit were needed. Houston, we have a pattern.

I used the pattern to cut two pieces of plywood. Time for an edge treatment. I routed a 1/2 by 3/8-inch rebate in a piece of birch 1 by 2. This would cover the plywood laminations on the edge of the table, flush with the top. A table saw and a 45º sled made quick work of cutting the birch edges to length. A quick glue-up and I was done for the night.

Let’s Finish This

The interior of our teardrop is varnished, and the wood and polished aluminum go well together. I sanded all the table parts and coated them with boiled linseed oil. We were running short of time before our trip, and the oil would protect the wood. I’ll add a more durable finish later.

Linseed oil dried, I mounted the supports to the table with piano hinges. Another trial fit, and all was well. Folded, the table fits flat on top of the galley storage for transport. Finally, I drilled holes through the steel straps into the galley edge and threaded them for thumb screws. This prevents the table from detaching while in use. Level and plumb, the galley was ready!

photo of Jim with the new galley table

Ready for camping!

photo of trailer front with box mounted

More Storage – A Trailer Tongue Box

Jim, May 17:

photo of the bare trailer tongue

Bare trailer tongue

During the Big Bend trip, I started to think about refining our trailer and realized that storing jacks and other trailer equipment in the galley complicated our setup. A second storage area would make the galley more convenient and allow Marilyn to start our evening meal while I was setting up camp. I had seen boxes that mount on a trailer tongue, and thought that might be the answer. They aren’t hard to find, and I soon had one on order. Made by Better Built, and 34-inches by 19-inches and 18-inches high, it looked like it would just fit on our teardrop’s small tongue.

The new trailer tongue box

The new trailer tongue box

In hand a few days later, it looked great and didn’t weigh much — welded aluminum construction with a locking latch and power-assisted top hatch. Our trailer has a single rail for the tongue however, and it looked like the box was better suited to trailers with a “y” front hitch. Mounting the soft aluminum box on a single rail seemed like a problem — the first time it was leaned upon, it would bend. I decided to get some help from my friends at Vintage Motor to make a stout steel mount. Jason and I quickly decided  to cradle the front and back bottom edges with 1 1/2-inch angle iron. These would be welded to other angle iron and attached to the 2 by 3-inch trailer tongue with bolts.

We set to work. After measuring the front and back box edge, Jason cut 16 and 34-inch pieces of 1 1/2-inch angle iron on a chop saw. By placing them under the front and back edge, we were able to mark the precise size and angle using a sharpie. Using these marks, he was able to trim the rails with a pneumatic cut-off tool, and round the rough edges with an angle grinder.

Next, we cut brackets and holes and drilled them to accept the tongue bolts. They were then welded to the rails. There was one bracket per rail, and they were placed so that the rails would be centered on the trailer tongue with a bracket on each side. Finally we drilled four holes on the long rail, and two holes on the short one to mount the box.

Rails and brackets complete, it was time for a test fit. Everything seemed to work, so I set about drilling bolt holes into the trailer tongue. This is very tough steel, and it took awhile — even with the help of my grandad’s 1/2-inch drill. Now we could bolt the rails on, and set the box into them. Last, we drilled holes from the bottom, through the rails, and into the box. It was secured with six bolts as well. We’d had to “fudge” the fit to straighten to box and allow for lid clearance with the trailer, so the front rail was a little off-center. A trip back to the shop to adjust it’s length, and we were ready for paint.

Now painted, it was time for the final installation. To protect the bottom from being dented, I’ll cut a piece of plywood to fit the inside. The box size seems proportional to the trailer — a lucky break. I was also pleased to see that the diamond plate on the trailer matches the box, both in pattern and rising to about the same height as the diamond plate on the trailer. Looks like a custom fit!