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September 2, 2015 Camping Projects

Homebuilt Teardrop Trailer 7: Hatch Construction

This post contains affiliate links.Part-7-Homebuilt-Teardrop-Trailer-Build-Journal

This post is part of a series documenting our homebuilt teardrop trailer, reviewing the construction and installation of the rear hatch. Please scroll to the bottom of this post for links to previous articles.

Back to it! Apologies for the delays (of like 10 months, oops!) since the last post… we're getting back to having them all posted in September and maybe into October.

The hatch being built was a big exciting step for me, because I could finally, REALLY, visualize what the finished product would feel like. I spent a ridiculous amount of time opening and closing just the skeleton frame of it, until Jamie shooed me away to keep working. It was very cool to see how close it was to being done at this point!

The hatch frame is made from poplar and plywood; the curved sides are cut plywood, using a router with a guide bearing and the same template as the sidewall. The crossbeams are solid poplar.

01 teardrop trailer hatch closed

We used a single “hurricane hinge” to attach it at the top; it's watertight and runs the full width of the hatch. (This one is similar) We had found an old piano hinge at a garage sale, but decided the hurricane hinge was a better choice because it's both watertight and could be cut to the *exact* width we wanted. Also, in case anything were to happen, the hatch remains removeable (not easily, but doable) in case we ever need to make repairs or changes to the hatch.

02 teardrop trailer hatch open

Once the hatch frame was done and the glue was dry, we skinned the inside with 1/8″ plywood and painted it to match the inside ceiling. The hole seen below is part of the latching system that was installed later. (It was later covered with a small panel of wood, so we can access it again if needed for future repairs.)

03 teardrop trailer hatch skinned inside

Test fitting the inside skinned hatch; notice the rods sticking out of the sides; those are part of the locking mechanism before they were trimmed to size.

04 teardrop trailer hatch filling

05 teardrop trailer hatch fitting open

06 teardrop trailer hatch fitting side view

The locking latch; the rods latch in place, in holes in the sidewall frame, it's called a “t-handle” latch and we found ours at a car parts resale shop… but you can also source it online.

07 teardrop trailer hatch latch

We then skinned and varnished the outside like the sides, using the marine plywood again. We used the same system of straps, glue and pin nails that we used to get the curve of the front as well.

I don't have any photos of us actually sliding the hatch onto the trailer though, because it's a 2-person job, so I couldn't be taking photos! LOL

08 teardrop trailer exterior skin

And the last thing? How to keep our lovely hatch from crashing down upon our heads while camping. We used 150 lb. hydraulic struts; more weight than we really need (the hatch weighs less than 100 lbs, and we have two struts holding it up) but with wind and better-safe-than-sorry, we went for the heavier weight capability.

hydraulic hatch

They leave the hatch easy to open and close, but we wanted to add another, secondary, safety mechanism.  The solution? A piece of copper pipe that fits right over the base of the strut, so even if it's pulled on, the length of pipe stops the hatch from coming down all the way. It's simple to move it, you just need to shift it up to the other cylinder to get it out of the way so you can close the hatch. Safety first, people!hydraulic hatch safety

Next post: Child's Hammock Bed

Previous posts: Planning & Framing | Walls & Interior Skin | Galley Counter & Flooring | Insulation | Interior Ceiling & Fan | Exterior Wood Skin & Sealant


10 Comments

« Gish-wha? Team Lagniappe and G.I.S.H.W.H.E.S 2015
Thursday #386 »

Comments

  1. Anne (@notasupermom) says

    September 2, 2015 at 8:51 am

    I’m continually impressed with this project!

    Reply
  2. Allison Waken says

    September 3, 2015 at 11:10 am

    This is SO awesome! I need to do some work on our popup that suddenly seems like nothing compared to this project. Can’t wait to see more!

    Reply
  3. Scott says

    September 28, 2015 at 12:23 pm

    Like your project, thanks for the tips!
    How did you attach your aluminum sheeting?
    What thickness of aluminum sheet?

    Reply
    • Lizz says

      September 28, 2015 at 12:40 pm

      Hi Scott, I want to say it’s 1/8″? It’s held on with a liquid adhesive. The specifics will be in post #10, coming up at the end of this week or next week. 🙂

      Reply
  4. Eric says

    November 17, 2015 at 11:20 am

    Love the project and the great write-up! I’m looking forward to the last post.
    What are the rods that you used on your latch and what is your source for them?
    Thanks!

    Reply
    • Lizz says

      November 18, 2015 at 7:42 am

      Hi Eric, thanks for stopping by! My husband says he *thinks* he got the rods at Camping World, but isn’t 100% sure. They’re made for that use, though, to connect to the lock part, so if you find the lock, the rods should be nearby. 🙂

      Reply
  5. Lynda says

    November 20, 2015 at 12:07 pm

    Hi. I have a secondhand teardrop with leaking problems. How did you seal the joint between the body and the back hatch (kitchen) that opens and closes?

    Reply
    • Lizz says

      November 20, 2015 at 3:12 pm

      Hi Lynda, It’s a “hurricane hinge” so it’s solid piece that routes the water off the sides.

      Reply
  6. Bob Lowe says

    April 1, 2016 at 11:57 am

    Thanks for the post. I think this is awesome. I would love to build a teardrop trailer. It would be really cool to be able to customize it how ever I would like. Thanks for the tips.

    Reply
  7. Mark says

    January 1, 2022 at 1:11 pm

    I’m not having success linking to the other earlier design and construction information. Links take me to other content. Suggestions?
    THANKS

    Reply

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Welcome, I'm so glad you're here! Thing number one, I'm tall. I've been told I should have a warning on my blog, so here it is! I am taller in real life than I appear on the internet. Want to know more than this "short" version? Go here to read more about me and my family, and for links to some of my favorite posts.
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