Gypsy Wagon Construction

instructables

Gypsy Wagon Construction

by GeorgianBay Scott

the georgian vardo ( Sold ... another vardo build in progress).

Updated : August 15, 2015 ...... Finished picturesposted under step 10____________________________________________________________

I am posting a photographic journal documenting myprogress as I build a gypsy wagon. I have named her,the 'Georgian Vardo'. The pictures have beengrouped into nine steps of construction and one pageof materials. The dimensions can be found under step11. As of August 15, 2015, the georgian vardo isessentially complete. Construction time was just over3 months, working on it in my spare time and on mostweekends.

I have no 'detailed' plans for building a vardo. UsuallyI design as I build. As with any project I take on, theinclusion of creativity or whimsical craftsmanship is amust. The same has been true with the constructionof the gypsy wagon.

Although the interior construction of the wagon ispretty well complete at this point, it needs decoratingand some whimsical touches. Feel free to makesuggestions in this area as my spouse will argue Ihave zero decorating skills. Readers will probablyunderstand the construction steps from the pictures(many with instructional comments) and, althoughsequentially posted, you can feel free to contact me ifa step is not clear. Some additional details and a fewmore pictures can be found athttps://georgianvardo.wordpress.com/

For the most recent adds and modifications refer tosteps 8, 9 and 10.

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Introduction

About a year and a half ago I discovered a gypsywagon several kilometres from home while on a walk.Forgotten and a little worse for wear, it was parked inthe backyard of a home, being used to store unusedgarden tools and flower pots. There was somethingabout it and the dozens of vardo pictures I discoveredonline that held my fascination as a woodworker andwood artist. It was rustic art on wheels. Unlike thebeat-up discovery down the road, I now understandthat historically, gypsy wagons, caravans or vardoswere four-wheeled horse drawn living wagons. Theywere often intricately carved and vividly decorated.When I first saw one several months ago I wasamazed at the detail and artistry that the builder hadput into her wagon creation. Now there was abackyard woodworking project! It had all the elementsthat attracted me to do the same. And so I decided “Iam going to build me one of those”.

Gypsy wagons can be grouped into different stylesincluding the Brush wagon, Reading, Ledge, BowTop, Open lot and Burton wagon. I think I like theReading and Ledge style the best. Perhaps I couldcombine the two styles and use a recycled twowheeled utility trailer as the vardo base frame. Idecided I would build a wagon built on a 4¢ X 8¢ trailer

Gypsy Wagon Construction:

http://www.instructables.com

http://www.instructables.com/id/Gypsy-Wagon-Construction/

http://www.instructables.com/member/GeorgianBay Scott/

http://georgianwinds.wixsite.com/thegeorgianvardo

https://georgianvardo.wordpress.com/

https://georgianvardo.wordpress.com/

http://gypsywaggons.co.uk/varsuk5.htm

frame, remembering that the teardrop I rebuilt lastyear had an interior space of just under 4¢ X 6¢.Adding the ledges would give me 6¢ X 8¢, double theinterior compared to the teardrop and more than bigenough for a tiny wagon. Besides it would be easierto move around both while building and later whenpositioning at a campsite.

Using Kijiji, I located a well used but solid utility trailerwith a heavy duty frame, axle and tongue jack thatmet my requirements. And it was cheap. I beganconstruction in late April, planning on a 6 - 8 weekbuild. As of today (August 9, 2015) I have about 90%of the exterior completed and inside I have completeda single couch / bed that extends to double bed(gaucho style). Will be adding a few more curlybrackets, colourful trim, some shelving, an exteriorlamp outside the door and perhaps a kitchen galleybox. Will try to keep the picture gallery updated untilthe vardo is completed. By the way, it would be greatto meet other local gypsy wagon builders. Feel free tocontact me.


https://georgianvardo.wordpress.com/contact-me/

Step 1: Materials and Tools

Materials and Tools

The material list is from memory and the exactquantities have not been recorded. This is most of itthough.

MATERIALS:

50+ 6’ tongue and groove 3/4 x 5" pine boards

10+ 8' tongue and groove 3/4 x 5" pine boards

2X2's for framing walls (I used finger joint kiln driedspruce)

5 knotty cedar 8' 2x4’s for ceiling rafters

a few 8' 1x4's for door and window trim

2 8’ 5/4”x12 pine for ledge brackets

a gazillion feet of 5 foot cedar fence boards, ripped to2” and a few to 2.75” for battens and corner trim

1 sheet 3/8 ply, 1 sheet ½ “ ply and 5 8’ PT deckboards (5/4”) all for the floor

Construction adhesive and exterior wood glue

Small box of 2.5” self drilling screws for fasteningfloor to steel frame

Box each of 1.5", 2” and 3” deck screws

Box of 1.5” roofing screws with neoprene gaskets

3 or 4 windows and an old door from the Restore(local used construction materials) – 4 windows and 1door cost me $30 total

3 sheets (4' X 8") of mahogany veneer ¼” ply forinside ceiling

3 sheets of galvalume steel roofing

One used 8 x 4' utility trailer

Polyurethane, stains and paint

4 gate hinges and 1 gate latch

several pieces of embossed pine moulding ( 8'lengths)

several pieces of aluminum trim ( 8' lengths)

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Tools:

I worked with dimensional lumber where possible sothere would be no need for planing.

Table saw, mitre saw, handsaw and hack saw

Carpenters square, speed square and adjustablebevel square

Hammer, screw drivers

Impact driver, drill and various bits

Hand plane and jack plane

Tape measures and pencils

Several ratcheting bar clamps (short and long)

Pair of saw horses with a sheet of plywood

A random orbital sander

Jig saw or scroll saw ( I used my band saw for all thebrackets)

Paint brushes and sand paper


Step 2: Begin by Building the Basic Box

I began with purchasing a used, heavy duty utilitytrailer. The wood floor and side walls needed to bereplaced but otherwise it was solid and the right pricefor my project. If the frame needed any modificationor strengthening, this would be the time to do it.

The floor was built as a 'sandwich' from 3/8" ply, then

5/4" PT deck boards and a top sheet of 1/2" ply. Theroad side of the bottom sheet was given 2 coats ofexterior stain before laying it down. The deck boardswere screwed to the steel frame using self drillingscrews.


Step 3: Building and Raising the Walls

The two side walls were built on the ground and lifted into position. The top and bottom plates were bevel cut at 7degrees so that they would angle out from the ledge. This bevel cut was done before attaching the vertical boards(wall studs).Actually, this step was by far the quickest & easiest part of the construction.


Step 4: Adding the Siding

This was quite time consuming at first, making certain that each course was level to the board on the opposite sideof the door. None the less quite satisfying to see the walls go up and for the wagon to start taking shape.


Step 5: Building the Roof

The basic idea I had here was to run three cedar 2X4's from front to back. They would sit on and be attached to a'bench' above the door and the end window. I bevel cut the 1st and 3rd beam. The top of each wall was previouslybevelled so now there would be 5 beams to bend a sheet of thin (1/4") ply over the beams and following the curveof the top of the wall. The whole structure was amazingly strong once it was all connected.


Step 6: A Few Exterior Details


Step 7: Roof Trim

A work in progress. Ends are weather sealed. Decided to add a couple of decorative brackets at the door end,outside wall between the ceiling and wall. Those are trivets at the top of the door frame.


Step 8: Trim, Door and Paint, Paint and More Paint

I used a good quality exterior latex paint with built in primer. Two coats. Cut all the brackets using a band saw.


Step 9: Gaucho Bed


Step 10: Finishing Touches

I think I am done. Now for the fun part. A second road test tomorrow and then a few small camping adventures atnearby campgrounds. Most of my friends think I have lost it and are shaking their heads. Oh well, I built it for me.


Step 11: Dimensions

Vardo Dimensions

The used utility trailer I found was roughly 4’ X 8’with14” wheels. With the original weathered woodremoved, the inside of the trailer frame measured 50”X 98”. This caused a bit of a problem initially, but Ibuilt it to accommodate 8 foot plywood for the floorand side walls.

· Box width = 4’

· Box length = 8’

· Ledges = 12”

· Length of sleeping bed frame = 74”

· Width of sleeping bed frame = 48”

· Walls = 46” along the hypotenuse

· Wall angle = 7 degrees

· Distance along arc of roof 96”

· Height from floor to midpoint of roof = 80”

· Door height = 72”

· Weight (estimated) 1000 lbs. Tongue weight (notknown)

See my rough drawing plan. Pretty well went with thelook and shape but redesigned as I went. Dimensionsabove are accurate.

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Currently I am completing a number of modificationsto a new teardrop camper that readers may beinterested in seeing. Some of the mods and add-onsshould work with other models of campers.https://www.instructables.com/id/Thirteen-Teardrop-Camper-Modifications/

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https://www.instructables.com/id/Thirteen-Teardrop-Camper-Modifications/

Hi Scott. I'm admiring your work...and trying to steal ideas for my first build! I have my walls framedand I'm looking to start the roof. I'm hung up on the arch. How did your friend calculate the arch ofthat template?

Cheers

It was her idea but here is how I adaptedit. On a sheet of ¼ inch plywood that is at least a foot wider than the vardo,draw a series of arcs, varying in height but having exactly the same width ofthe top of the wall. Then tack the sheetto the wall, stand back and pick the arc that you prefer. I chose one that wasapproximately 18” higher than the top of the wall. Your choice. Now cut out the sheet along thechosen arcusing a jigsaw, re-attach to the end wall and nail or screw the remaining wallboardstemporarily. Using the plywood template as your pattern, draw the arc onto thetop boards, then remove the template and top end boards, cut the curves andreattach. This is more difficult to write than to actually do. Hope this makessense, and good luck with your project.

like Tinkerlady and Jay, I love the style though like most people I want to do it a little different. Afew months ago I dumpster dove and came home with about 26 triple pane plexiglass windowsthat are about 5'x5', with the outer pane being opaque. I'm planning on using a couple to form a Vin the front to cut down on wind resistance and also allow the light to shine through. I've got somemore ideas I want to build into it but it would take to long here.

One question , how did you seal up the roof so that the front wouldn't leak?

Short answer, lots of caulking. I ran a thick bead of caulking around the top of the wall beforeattaching the the roofing which over hangs by 4 inches at the front. Then caulked again on the


outside after the roof was secured. The ran a piece of trim on the outside all around with anotherbead of caulking under that. The three layer roof was sealed on all edges using ice and watershield before attaching the eave. I think the pictures in the steps show each of these details. Goodluck with your project.

A few of you have inquired about the weight and I can only estimate as I have not taken it to ascale. Using an approximate weight for the number of square feet of lumber used, and then addingin 100 lbs for fasteners and the roofing, I would think the total weight (not including the trailer frameitself) would be between 750 and 900 lbs.

Great job! I was planning on building a teardrop but this project is making me think twice.

Thanks. I have built both. I'm in the process of steampunking the teardrop that I restored last year.Lots of copper pipe, brass, taps, guages and retro whimsy. Will post a short instructable soon.

I absolutely have to do this! Fantastic work!

This is just brilliant. The trim details are so perfect. A genuine work of art. How about some fauxwooden spoke wheel hubcaps? I know you'll enjoy every moment spent in your 'georgian vardo'.Great work!

I agree with tinkerlady. This is brilliant, and I too want one. Some better day, perhaps when I havea little more time.

Brilliant. I am amazed, and I want one. This looks like an awesome place to hang out and drawinspiration for more projects. Well done!!!

Well thank you tinkerlady. And you are correct about the inspiration. Decided last evening that itneeded some homey comfort decorations ( gypsy style of course). Perhaps my daughter willadvise. I will post an update in a couple of weeks.

love it

Love it.

love it

Thank you. So do I. First camp adventure with the vardo next weekend.

Love it hope I can do the same very soon.

Thank you. Since retiring a few years ago, outdoor projects, woodworking and a return to campinghas been most enjoyable. In fact I was working on the interior of the vardo when your msg arrived.Enjoy your wagon building once you get started and be sure to post some pictures. Cheers fromOntario, Scott

If you have any more pictures of the process, it would really help people follow what you did.


Gypsy Wagon Construction

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