Background
In 2023, I embarked on an exciting project to rebuild my new-to-me water-damaged Little Guy 6 Wide teardrop trailer. This comprehensive renovation breathed new life into this camping companion, transforming it into a more functional and personalized adventure vehicle. Here's a detailed look at the process, challenges, and results of this DIY rebuild.
When I bought the trailer for this project, it had been sitting unused for a couple of years. It had been covered with a tarp, but it was damaged and blew off unnoticed. Sealants quickly deteriorated and water got it in at multiple places. This added to the already high level of moisture in the trailer due to condensation. There was visible water and rot on the floor at the front and soft spots in the galley as well. I wasn't sure if I was dealing with a repair, or a complete rebuild. Only by removing the finishings and completely drying out the trailer would I be able to see the real extent of the damage.
Project Overview
The rebuild was necessitated by water damage, but I saw it as an opportunity to upgrade and customize my teardrop trailer. The project encompassed several key areas:
I decided to repair the sides instead of replacing them primarily due to the cost of the Filon sheets that would have been required. The original sides were laminated together and separating them proved impossible.
Electrical Diagram
Trailing Wiring Diagram
- Structural repairs
- Electrical system overhaul
- Interior redesign
- Exterior improvements
Preparation and Demolition
The first step was to strip the trailer down to its bare bones. This involved:- Removing cabinets, floor covering, and wall coverings
- Dismantling the ceiling, including insulation and finish
- Taking off doors, fenders, and lights
- Carefully removing side cladding
Structural Repairs
With the trailer stripped, I focused on repairing the damaged areas:- Repaired sides and bottom edges using biscuit joints, glue, and pocket screws
- Installed a new floor and underbelly
- Rebuilt the hatch frame and rear panel
- Added support for a future roof rack
Electrical System Upgrade
I completely overhauled the electrical system, incorporating both 12V and 120V components:12V System:
- Installed a 100W solar panel with controller
- Added a LiFE battery with disconnect and monitoring systems
- Incorporated exterior and interior LED lighting
- Installed USB charging ports
120V System:
- Installed a 3-circuit breaker panel
- Added a shore power connection
Electrical Diagram
Trailing Wiring Diagram
Interior Redesign
The interior received a significant makeover:- Installed new wall and ceiling finishes
- Added foam insulation for better temperature control
- Built and installed custom cabinets
- Installed a sink with water inlet and drain
- Added a stargazer window for nighttime views
Exterior Improvements
The exterior wasn't neglected:- Installed new fenders and sealed them properly
- Added new exterior lighting
- Installed side vents for improved airflow
- Mounted a Maxxair 7500K MaxxFan with remote control
Challenges and Solutions
One of the biggest challenges was ensuring proper waterproofing. I meticulously sealed all potential entry points for water, including:- Around the new stargazer window
- All exterior light fixtures
- The roof-mounted solar panel and fan
- Final Touches
- Installed click vinyl flooring
- Reinstalled doors with new seals
- Performed a full electrical system test
- Conducted waterproofing verification testing
The Costs
Here’s a summary of the main categories and their costs for my teardrop trailer rebuild:- Trailer: $1,839.00
- 12V Electrical: $1,757.51
- 120V Electrical: $293.20
- Other (Upgrades): $1,798.48
- Repair Parts: $2,201.56
- Total Cost: $6,050.74 (Canadian, 2023)
Future Plans
While the rebuild is largely complete, I still have a few items on my wish list:- Installing an awning
- Adding a roof rack
- Incorporating a portable shower and toilet system
