Nest Caravans — Building a new FG trailer, step by step

[KevinScamps]

Is that receiver strong enough for a fully loaded bike rack? They have a lot of torque and bounce up and down with a vehicle. I would think you would want something longer. It looks like you have just bolted it to the wood and fiberglass floor.

[Ken C]

Wood? the build process shows no wood in the floor.

[KevinScamps]

Originally Posted by Robert Johans

For those of you who have expressed concern regarding stone strikes on our windshield, a colleague of ours suggested something brilliant: a soft, snap-on "mask."

This mask, with a thin, closed-cell foam center sandwiched between a Sunbrella-like cloth cover, could simply be rolled up and stashed when not needed.

What do you think?

Anysoft cover is going to look like crap in two years in the Colorado sun, or be moldy in Oregon. And for that matter is going to scratch the window in no time unless you put in some space. Though it looks like you might have space because the window is set into the fiberglass... hard to tell. I would lean to a rigid piece of foam with a thin plastic hardshell. That way it can be light, tough, insulating, shouldn't fade in the sun like a cloth cover, and fully removable for maximum sunlight when parked. Shouldn't need to be more that 1/2" thick. If you can't make it light, make it in two seperate pieces. Rock strikes are going to be at the edges of the windows anyways so if there is a small gap in the middle it should not be a problem.

[KevinScamps]

And I think I pretty much described a lighter scamp rock cover.... Except foam and fiberglass (or plastic) instead of solid fiber glass with an easier connection technique. I kind of like the idea of a rail or connector at the top you simply hook the panel over and then buckle it down at the bottom. Making it in two pieces should make it possible to make it much lighter and easier to connect.

[honda03842]

We've had two small trailers with front windows and rock shield covers.

Our Sunlight had a permanently mounted rock shield with adjustable arms. Our Scamp has a removable rock shield that we made permanent with fixed arms. Both were fiberglass.

Removable rock shields, whether hard or soft, are a bother to have to store when camped. Their advantage is they don't scratch the window.

The Casita we used for year had a fabric cover for the front air conditioner used in Casita 16s. It was 15 years old and was still in good shape un-effected by sun and sand, though I expect covering a window with fabric would eventually result in scratches.

Our CRV came with a cloth lined 'bra' to protect the front of the vehicle. It did not take long for the inside cloth to become loaded with dust and what ever.

I think the fact that so many trailers with front windows have shields indicates the need, at least on some tougher roads.

[Robert Johans]

Originally Posted by KevinScamps

Is that receiver strong enough for a fully loaded bike rack? They have a lot of torque and bounce up and down with a vehicle. I would think you would want something longer. It looks like you have just bolted it to the wood and fiberglass floor.

If, by fully loaded, you mean two bikes, then yes. Remember, the Nest is targeted towards couples, not families.

And as Ken C. points out, absolutely NO wood in the floor. And because of our unique monocoque design, and infusion construction process, the fiberglass lay-up schedule through which the receiver is mounted is very stout -- engineered specifically to carry that load.


Sent from my iPad using Fiberglass RV

[kkinna]

Sent from my SAMSUNG-SGH-I467 using Fiberglass RV mobile app

[Robert Johans]

Getting down to the last bits of design, fabrication and construction. Door assembly, including hinges and door latch. Final window trim. Fine-tuning the body work.

Though production models will feature a standard gel-coat surface, the prototype will be painted. Assembly of this first unit required a lot of test fitting, and frankly, we ran into a few snags. (i.e.: I messed up and cut holes in the wrong places! Good thing FG is relatively easy to repair!) Looks a little rough right now, but the body components go to the paint shop on Tuesday.

Inside, the rough wiring has been laid, and the insulation installed. You might be able to see the FG brackets mounted to the walls to help support our cabinetry.

[Robert Johans]

A 20-gallon gray water enclosure is sandwiched between the shell and the shower floor. A large deck plate (not shown) has been installed through the floor for easy access from below to the tank's insides.

These shots aren't great, but you can see the shower enclosure has been assembled and waits to be permanently mounted into position.

[catholiccamper]

As for a name...why not Refuge. A Nest is one after all and what we're looking for when we're camping. Just a thought. Greg

[June Bug]

Any updates on seeing the completed prototype?

[Lv4toys]

I was reading another thread that mentioned that it was estimated by Mr. Johans (in an e-mail to a member) that it would be another six weeks before the prototype was finished.

The Nest is definetly on my short list, when we are ready to upgrade trailers.

Love the photos!

[Robert Johans]

And we're back...

Nest will be offering tow vehicle color matching as an option, So we painted our prototype to match our silver Cherokee (a mid-size cross-over with a 3500 lbs towing capacity).

[cpaharley2008]

Sweet....

[cpaharley2008]

Robert,
Can that jack be turned 90 degrees to allow clearance with tow vehicle? The handle may be too close for some.

[Robert Johans]

With the Nest back in our shop we were able to affix the exterior components, cargo access door, utility ports, taillight bowls, DOT lighting, etc.

[Robert Johans]

Hitched to the Cherokee, its off to the upholstery shop for interior wall covering. (Side windows and wheel flares get installed upon its return to us.)

[Robert Johans]

Should the jack handle get too close, it can indeed be rotated.

[cpaharley2008]

Thanks Robert, keep up the great work and postings.

[brian m.]

REAL sweet!
It's fun seeing it all come together.

Any chance we could soon see some photos with a person next to the trailer for a sense of scale?

Thanks Robert!