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.

Step 1: 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.

Comments

[Kris T.]

Gypsy wagons and VW Beetles are similar in that you can paint them any and all crazy colors and they still look awesome. Thanks for posting!

[PaddyODill]

Do you have a bill of materials that I can get? email me at [e-mail]

Thanks

Peter

[gypsynana]

I think you did a great job! I would love to do something like this to my old (seen it's better days) ''74 Chevy Motorhome.

[dizzle976]

your awesome drafting skills disgust me as mine look like a dizzy 3rd grader got hold of a crayon. how does it handle with the wind while towing?

[paleotool]

She is so light that she handles fine. With my heavy Ford truck I hardly felt it when I lost a wheel even. My Tacoma, I only notice in a severe cross-wind. Never an issue yet and I live on the Plains!

[fringetree]

As I am getting older, I want a Vardo for SCA events. Your plans give me a starting place. Now I have to figure out how to make a fold-down one as I do not want the wind drag when I'm driving to an event 600 miles away. Excellent photos and information. Would appreciate a materials list so I have a rough idea of expense. Already have the trailer and a lot of things to put in it since I already use a tent about 12 times a year and one of those times is an 8 day camp.

[krimini]

Thank you for sharing your drawings and all the info on how to build this Wagon... as I mentioned in my other post, due to an unexpected major accident it is highly unlikely I will ever be able to have one lie this for travel, but I think the plans could still be invaluable in setting up the perfect, stairless, land based Wagon on a small piece of family lake front property that always seemed to tiny to build any type of real place to stay, so I have always just made do with a simple tent set up for weeks, even months while out there. Not super comfy, but fun, but with my new ability issues, and need for real support when sleeping, etc. I believe this could be the perfect solution as it is a very narrow strip of land with only a small clearing a land regulations for that region do not allow the removal of any trees. This means I have about a 10x12 ft sized fully cleared region to build, and this seems to be the perfect solution... especially with the wood stove because living in the Pacific Northwest has also meant I don't get to spend nearly as much time at the lake, away from everything else... not with only a tent for protection, and when I can't even get my van down there! With one of these wagons built there, without the need for wheels, and with most of the stove pipe inside and foam board insulation to increase the warmth all year long, I might finally be able to enjoy getting away from my daily city life much more easily, and as often as I want! Thank you for opening up another door in my life which now deals with many more closed doors than I ever knew existed prior to being the victim of a hit and run left with over 100 broken bones, including 3 in my neck. Thus my odd request in any help in making my van, more wagon like, or efficient. One last query... If I really wanted to go for the unique look of Gypsy Wagon using a VW van, would it be at all possible to actually add wood sides to the body, and shutters to the outside of the windows? At the very least, the shutters, but ones that actually open and close... It may be a strange hybrid, but then I could come as close to my Gypsy Wagon as I may ever get. Thank you for your patience, and I truly hope you, or your followers have some ideas to help me adapt my van.

[krimini]

I have what may be a couple of truly strange questions , but any and all feedback would be greatly appreciated. I have a 1984, fully camperized, pop top VW Westfalia. Over the years I have found many ways to make it more and more homey, but some things I just never really figured out. Seeing the usage of space and such in this fabulous Gypsy Wagon will help that to some degree already. Here is where the odd sounding part potentially comes in. I have always wanted to find a way to get rid of the back lift up back door and replace it with two doors that open outwards. Easier fir me, as I have had an accident leaving me with various, permanent disabilities. I am also wondering about 2 other ideas... Is there any way to convert the fridge and stove from propane to solar? Second, and probably craziest sounding, is if it would be possible to have it so that the main bed can actually slide out the back of the van, have a couple legs that snap down for support and allow me the option of sleeping outside, under the stars. I never would have thought of it until I recently saw a photo of the new VW Transporter that already does this. More info on the Transporter can be found at http://amzn.to/XIb3Jw I always wanted a Gypsy Wagon, and often thought of building one, I even set my van up as much as possible, using storage and decorating ideas from research on them. Due to the extent of my recently acquired disabilities though, I suspect my van may end being what I need to work with instead as stairs, a bunk style bed, and many other even minor aspects would now be great barriers for me to try to overcome day in and out. Thus my desire to try to work with what I have. What was intended to be a temporary option looks like it may now need to become a long term one. So any and all ideas regarding the changes I would like to make would be immensely appreciated! Thank you, eve if it is a bit off topic... BTW if you were to mount solar lanterns (not unlike those used to light up ones garden or walkway) you would then have easy lighting to come and go day or night with no reliance on anything but Nature! I have two on the outside of the van (mounted with those rolling holders intended for mops or brooms), and a few in easy access of light inside during the day, and they not only provide plenty of light for anything, even reading at night, and a decent set can last for ages... Mine are now entering into their 8th year and since they were fine all last year, I am gonna guess I will get at least one more year out of them!

[penny049]

Too cool! I want one!

[calauctions]

I was just asked by a friend to sell his for him - He spend 2 years and over $50,000 making his from ground up. If any one is interested in buying this please call me at six one nine - 326-9690. Located in Southern California and is in almost new condition...

Here are the specifications:
2006 Custom Gypsy Wagon RV Trailer, 2x6 Steel Frame Professionally Built by P2K with HD Axles, Springs, and Brakes, LED Lighting, Stabilizing Jacks, Includes Tow Hitch, Weight Distribution System and Sway Bar - 2 5/16 ball. Framing 2x2 square steel tubing, roof is Galvanized Steel Sheet with new rubberized coating, Siding is Red Oak Tongue and Groove with insulation. RV Awning with Side Curtains, Fold Down Outdoor Table, 40 Gallon Black Tank, 35 Gallon Fresh, 3 Way Refrigerator, Porcelain Toilet, Shower, Water Heater, Stove, Double Sink, Bunk Beds, Oak Table, All windows are made of Lucite, Penny Board Paneling on walls, New Stain on Exterior. Used less than 1000 Miles. Registered permanent trailer- Fees are very low. Currently Registered. 8 foot 6 wide, 10 foot 6 tall, approximately 6000 lbs, Vin 00009 Everything works and is ready for your next adventure.

[kkastel6]

Just want to say, you've done a great job on this wagon. A total inspiration. Am building one over the next couple months. Am curious to know if you did install another window for iimproved ventilation as well as vent above bed?. Also in the discussion below, you said you added another layer of wood to side walls to keep wagon cooler in heat. Did you add insulation between? As to floor, did you insulate or use marine ply? I work up in the Gila 85 mi from T or C 9 months out of the year & intend to use my wagon for off time exploration in the SW & elsewhere. Thanks,

[paleotool]

There is NO INSULATION, in the modern sense, anywhere in the wagon. No new windows yet but hope to make the decision over the winter, when it's easiest to work outside here. There is a solar powered vent over the bay window which make a world of difference in circulating the air. There is a 1" dead-air gap between the inner and outer walls that works well to insulate, but I may break down and fill with rigid foam someday based on some good advice from a builder friend. The floor is 1" exterior plywood underlayment covered with 3/4" oak planking.

I love the Gila and I wish you well on your build.

Updates to the wagon are documented on the blog site as I consider it an ongoing process, evolving with my needs, whims, and cash flow.

[joe karr]

Spectacularly simple. I am impressed with how you pushed the limits of frame construction, forgoing typical 2x4 framing and looking at it as a"box". very interpretive and adaptable. pivot window, nice. no plumbing! light, single axle, easy to tow, i am dwg mine up right now. the purlins work fine i suppose? I need more insulation, norcal gets chilly. There is tiny potbelly stove in my shop that will be perfect. I am a blacksmith, so if you need some trade points, or a tomahawk, let me know. I also see the bows, antler points, bone needles and tools as positively epic. i know the challenge. keep on.

[Funky Chicken]

Hi George. I've admired your vardo for quite some time while we have been designing our own. Ours has a lot of similarities to yours with inspiration directly from yours and other sources.
I like the way yours is laid out very much. We have to consider hot temps more than cold, so we have to figure the bed situation to not cook someone in a box on the floor with no ac.
We have embraced your ideas for building no complicated systems into it. Thanks for that. Sure simplified the build. We also have a metal frame welded up with an aluminum skin from the get go so it will stay light weight. The wooden parts are being painstakingly pieced together by us now.
Thanks for your blog and instructions. It sure helps when we don't have to reinvent things.

[mburton8]

Hi, I am also interested but don't know how living in TX, I could go without AC.

[paleotool]

Add an AC unit? As long as you stay near power, it shouldn't be a problem. Or ad an RV electric system and an RV AC unit?

[xanxor]

Can you provide any more info on how you tied the box to the trailer?

I'm planing on build a large 20x8 one of these to actually live in.

[paleotool]

It is through-bolted from the sub-floor inside and connected with "L" shape brackets around the frame that bolt through the side of the box. I think it would be better to weld a few square stell uprights into the front and rear of the trailer frame and bolt the front and rear walls directly to these to prevent any movement.

[xanxor]

Thank you mighty.

[wisconsinjimmy]

What does this lovely wagon weigh? Axle weight? Tongue weight? I would make one of these but in today's high buck gas and diesel it would have to be pulled by a light car like an Impala type.
Keep up the great work.
Jim

[kimmycricket]

Love it, love it! Nice work........could you give an over all price of what you put into this this little beauty?

[paleotool]

Thanks. It cost about $2000 in new lumber, fasteners and hardware above the trailer. I bought the trailer used for $500. It was all welded, heavy-duty frame. Lots of labor and love. I probably wouldn't sell one for less than $11,000 and this one, with all the little furnishings would need to go higher.

[Gearz]

would you be willing to send me the drawing for this? It is exactly what ive been looking forjust made plans to get a trailer

[paleotool]

The only drawings are those posted in Step 1 here or on the blog page. I have a goal to make a nice set of line drawings available for a small fee in the next month, but really, those posted are all you probably need to figure out the plan.

[Delirieuse]

What size trailer did you use? Was it a standard 6' x 4'?

[paleotool]

No, I forget the actual measurements but it is about 4'8" x 6. It was custom built for a specific hauling job and, as I understand it, essentially cut down from a larger size but lifted to ride level with a land cruiser.

[Delirieuse]

Neat, good to know. Thanks.

[Broberg]

Coming from the wilds of Wyoming, this is very close to the sheep herders agons all over. Some of the differences include the Stove pipe is inside the wagon for more heat; there are 4 wheels instead of the 2 and most of them are made completely out of the corrigated tin and left that beautiful grey color!

Awesome project! I wanted to build one for years and use it while traveling and if possible live in it while I was a Park Ranger in Kansas... I also wanted to take my parents 16' Lakota tipi and live in it for the 5 months I was there but both fell through mainly cause I was there was from January to May! My family wouldn't want to see me freeze on the Kansas Plains!

Thanks again for sparking that intrest in me again!

[jessyratfink]

I have always wanted a windstream... but this is several steps above that. I love everything about it. You did an amazing job!

[GlenfinnanForge]

I love it. Unique, beautiful, cozy and homey. Such a fantastic change from all the white plastic boxes being towed all over the country.

[samgroce]

WOW, and I thought teardrops were the coolest!!!!!!!!!!!!!!!!!!!!!!!!!!!!!

[paleotool]

Thanks! They are second coolest for sure. Standing up is awfully nice. And you can't play the fiddle in a teardrop.

[charmrus]

what if you can't play the fiddle at all? Will this make me "fiddlerable"?
just wondering ;>

[olmon]

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

[TheZuke!]

Nice!
To make it look a little more "authentic", maybe paint the wheels with
"wooden" spokes?

[paleotool]

I don't intend to make it look like something its not but I do intend to paint the wheels red.

[TheZuke!]

Red will be fine,
The "sporty" looking wheels it currently has just look a tad...
anachronistic?

[zapskate]

love the choice of words!!!! that word needs to be used way more often!

[chuangt2u]

Cool.

Very, very, Cool.

[Bubbler]

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.