Building a Gypsy Wagon

Building a Gypsy Wagon
For many years I have been interested in Gypsy Wagons or "vardos" and western sheepherder wagons. As it isn't practical for me to have an authentic, horse-drawn lifestyle I decided to make a version towable at highway speeds. After reading just about every book I could find on wagons, caravans, old-school RV construction and trailers, a model began to take shape in my head. For me, it needed to be short and maneuverable, sleep two to three people, and still have the air of old world craftsmanship. This meant not looking like a modern RV. My secondary goal was that it should cost as little as possible without sacrificing sturdiness or basic comfort. Finally, I decided on wood as the primary building material as that is what I am familiar with and is definitely a very cozy and comfortable medium for a living space.

Most of the actual work was performed with a table saw, band saw, drill, and a slew of hand tools as I found time around my day job. Although I don't really consider it "done", it is complete enough to use and is currently on the road.
 
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Step 1The Mock-up

The Mock-up
After about fifty sketches and lots of graph paper renderings, I decided I needed to visualize this in three dimensions. Here is my cardboard mock-up of the final design. An earlier version is visible behind it but this one had a lot of appeal for me. My requirements were 7' width for sleeping cross-ways, 8-10' long, and enough height to stand up in. A collapsible bed and table allow for a shorter overall wagon. The first drawing above probably gives the most accurate dimensions for the final product. You can see some changes in design even as I approached the final product.
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101 comments
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Feb 17, 2012. 9:58 AMGlenfinnanForge says:
I love it. Unique, beautiful, cozy and homey. Such a fantastic change from all the white plastic boxes being towed all over the country.
Jan 22, 2011. 10:59 AMsamgroce says:
WOW, and I thought teardrops were the coolest!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
Jan 21, 2012. 8:42 AMcharmrus says:
what if you can't play the fiddle at all? Will this make me "fiddlerable"?
just wondering ;>
Mar 6, 2011. 9:22 AMolmon says:
Most people do tend to think of teardrop trailers in the context of only having 40 or so inches of interior height, but that isn't necessarily so. The teardrop shape is equally well applied to a mobile dwelling with standing space and can have either an interior cooking space or the traditional teardrop exterior kitchen. There are even plans available for that style. http://www.mikenchell.com/VintagePlans/14%27caravan.pdf
Nov 15, 2010. 9:05 AMTheZuke! says:
Nice!
To make it look a little more "authentic", maybe paint the wheels with
"wooden" spokes?
Nov 16, 2010. 6:41 PMTheZuke! says:
Red will be fine,
The "sporty" looking wheels it currently has just look a tad...
anachronistic?
Dec 28, 2011. 12:04 AMzapskate says:
love the choice of words!!!! that word needs to be used way more often!
Nov 11, 2011. 7:02 AMAzizas Place, Cambodia says:
Cool.

Very, very, Cool.
Nov 10, 2011. 10:11 PMBubbler says:
Fantastic work and ideas. I have planned a box for my trailer, but your work has now transformed any ideas I had.

I was also pleased that you did a reasonably long trip for the test as well.

Great stuff.
Nov 10, 2011. 8:02 PMjukeyjean says:
Wow all I can say. Very beautiful.
Nov 1, 2011. 6:17 PMHI-WAY MAN says:
AWESOME, IDEAS A PLENTY. GREAT FOR A BUG OUT SHELTER.COULD BE REALLY SELF SUFFICENT WITH THIS TRAILER. INSULATED PANELS FOR YOUR WALLS AND ROOF WOULD HELP IN THE COLD.PERHAPS A VENT JUST BELOW THE PEAK ,OVER THE BED & TWO SMALLVENTS IN THE FLOOR {UNDER THE SHADED TRAILER WOULD HELP COOL THE TRAILER}FOLD DOWN PORCH WOULD BE COOL.

HAPPY TRAILS
Oct 6, 2011. 11:06 AMwizard124 says:
This is definitely one of the coolest instructables I have come across. Awesome job! Like everyone else here I wish I could climb in and leave the real world behind.
Keep up the good work.
Jul 27, 2011. 4:34 PMMDisdain says:
There aren't enough ways to express how much I love this project. I grew up road-tripping and moving often and always dreamed of a gypsy wagon. Now I just need to find the space to start one of my very own. Thanks for posting this!!
Jul 22, 2011. 9:41 AMbillbillt says:
THIS IS WONDERFUL!! I am tempted to build one of these and run away from it all...
Jun 26, 2011. 7:41 AMlove4pds says:
This is AMAZING!!! Have you figured out how much it weighs?
Jun 19, 2011. 3:46 PMDea della Luna says:
This is incredible! Definitely a project I am interested in! Thanks (=
May 1, 2011. 10:08 AMKarentoo says:
Brilliant!
Apr 22, 2011. 7:12 PMrusheggie says:
beautiful
Apr 4, 2011. 6:24 AMDusty82 says:
Nice job and an excellent build! I do have one thing to address though - secondary egress. I just finished designing a sheep wagon similar to the old horse drawn type and it will incorporate a wood stove like your vardo. I'm going to start my build next month. The problem that both sheep wagons and vardos have is that the stove is right next to the only exit. I would STRONGLY urge you to consider changing the window above the bed to the type that can be pushed open completely to be used as an emergency exit should, heaven forbid, something go wrong with the stove and it catch fire. I too am putting heat shields around the stove like you did, but the thought of being trapped in a burning trailer just makes me sick.

In some states, it's also the law to have an emergency exit in a trailer designed to sleep in. Again, I would strongly urge anyone considering a trailer build, involving a wood stove especially, to add at least a transom type window big enough to crawl out of to the front of the trailer to give you an emergency exit. It's better to have it and not need it than to need it and not have it.
Apr 19, 2011. 7:01 PMBGreenHVAC says:
If you follow manufacturers instructions, local building code, and a little common sense, you shouldn't have any issues with the wood stove. People have used these types of devices for thousands of years. Many of my neighbors, plus a lot of my child hood was around wood stoves.

I would still install at least one alternate escape route, but wood stoves are as safe as gas burning heaters. I would connect an emergency electric heater for when the coals burn out. I live in the mountains, so I built an electric furnace to automatically turn on if the main heater drops below 50 degrees.

My neighbor installed a wood-burning stove in an old camper. It works good for him. I offered to make a sheet metal covering with weather guard. If I can get his permission, plus make a weather guard, I would post it.

I like your build. Nice job.
Apr 9, 2011. 6:47 PMsteveastrouk says:
What a great piece of work, and a fine Instructable. Beautifully done.

Steve
Mar 31, 2011. 6:11 PMcraftyv says:
Absolutely Brilliant work. You are obviously very meticulous and the results show why.
I noted your comment somewhere in Forums about how to "Flag" someones off topic remarks. Please don't be distracted by "off topic" comments they are not worthy of your time. Simply ignore and they will die away. Great job.
Oct 5, 2010. 3:44 PMfrazeeg says:
Just a little nitpick - you can spruce up that pan image and remove that break by using a free software called Autostitch.

Other than that, nice looking project.
Mar 29, 2011. 10:08 PMfrazeeg says:
You misunderstand - I like the photo fine. I've done the same thing before I found out about all the nifty computer programs that can "fix" those line breaks. I'm a child of the computer age so these are the sorts of things I notice.

Not to spam your comment box with irrelevancies about photography and post-processing.

Anyway, I find the idea of the Wagon intriguing since you seem to be able to fit so much into so little space. It's refreshing to see, especially in this age of "bigger is better" everything. Why use more than you need? Efficiency is a beautiful thing.
Feb 21, 2011. 4:01 PMderyk the pirate says:
Hey Im utterly impressed....You did an incredible job and am plannin on makeing a smaller version for camping. Can I ask why you used 1/4 inch on the sides and not the 3/4?
Feb 21, 2011. 5:24 PMderyk the pirate says:
I have a PT Cruiser so I can only tow a 1000lbs and Im hopeing to keep it under 700...dont want to push my luck lol. Im thinking 5ft wide by 8 ft long and close to 5ft tall in the center.

Im in the SCA http://www.eastkingdom.org/index.html and Im tired of tents lol all the canvas and poles and it always rains lol. Just big enough for a queen sized mattress and a little cabinet to put a porta pottie in and room for some gypsy garb. Can stick the other junk down below when I get to the camp site. I want to s fald the mattress liek a futon to use it as a couch so maybe 4 people can hide out inside if its raining or something.

Can you send a link to the metal roofing material you used? Its makin my brain think up some ideas lol.

thanks
deryk
Feb 17, 2011. 10:31 AMsprocketscientist says:
Really cool and inspiring! I saw the plywood being used for roof, and it looks like a corrugated product on top of that. Is that metal roof sheeting? And is it screwed on with those neoprene seals or how did you seal that from leaking?

I am dreaming of making a similar creature that can be jacked up off the trailer for storage so that I can still use the trailer for utility purposes.
Jan 25, 2011. 7:08 PMcheshyrekatt says:
I see you cantilevered the door. Did you do anything special to support that overhang?
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Author:paleotool(paleotool)
Naturalist, scientist, builder, and maker.