Walls

The walls of the trailer are made from 5.2mm lauan plywood with a 1×2 / 1×3 /1×4 frame.

Laid out a sheet of lauan.
Marked/measured where the galley wall will be.
Cut the lauan so that the galley wall will be on the plywood joint.
Laid the pattern out on the wall and traced the profile and door opening
Cut/Glued 1/4’s to frame the outside, clamping glued pieces for 1/2 hour until dried.
Cut out door with Rotozip tool. I used the 1×3’s that I had cut for the door frame as a guide to be sure the cut was straight.
Put a 1×4 at the location of the galley wall and the cabinet wall in the front of the trailer. I will be making a dado cut in these locations once the inside plywood is in place.
Placed braces where the galley counter and interior rear cabinet will be located. I also put a vertical brace half way between the back of the trailer and the galley wall so I will have an attach point if needed.
Added insulation
Skinned the interior side of the walls. I used 1/4″ oak plywood for the cabin area and lauan for the galley area. The galley will be covered in Laminate when completed.
I routered a 1/2″ notch for the galley wall and a 3/4″ notch for the cabinet.
Cut a 15/16″ rabbet 1/4″ deep into the top inside edge of the cabin portion of the walls. This will hold the inside skin of the ceiling (3/16″ lauan) and the roof spars (3/4″). To do this I made an adjustable fence for the router and used a 3/4″ bit.
Trimed the galley portion of the side walls down 3/8″ to make room for the gasket seal. I did this by using the fence I made for cutting the rabbet and cut a rabbit about 1/2 way into the wall. Then I turned the wall over and used a trimming bit to finish it up.
Epoxy Coat 1. Sand. Epoxy Coat 2. Sand. Get really frustrated with epoxy. Break down and buy the expensive stuff. Epoxy coat 3. Realize why people are willing to pay $100+ per gallon for the “good stuff” (i.e. West Systems Epoxy – low viscosity – low odor – long setting time).
Attached the walls to the floor/chassis. I first made pilot holes with counter sunk holes for the screws. Then I put down a bead of Silicone II roofing caulk along the corner between the frame and the floor then I set the wall in place. Then I tacked it with two screws. The first side I also tacked in pace with a brace so it wouldn’t fall over during the rest of the process. Then, dipping each screw in wood glue I securely fastened walls to the floor. I added a temporary spar when installing the second wall to keep it in place.