Building the walls


I had to splce 2 3/4″ 4x’8′ sheets of ACX plywood to make each wall panel. CDX could be used and is cheaper but it contains many more voids and imperfections which could compromise the wall.


I used a half-lap joint 3.5 inches across to join the two sheets. I use a straight edge and a router to remove half the material on the lap joint.

IMG_5153 IMG_5156

The sections were joined with Titebond III and as much pressure as I could apply. There is a saw horse located directly beneath the joint supporting the load on top.


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  • It’s probably right in front of me somewhere but what did you skin the inside of the walls with?

    • 5’x5′ 1/8″ baltic birch plywood.

  • Ian Moore

    Hey Ryan,

    Just curious – you used epoxy on the edges of the walls where they come into contact with the metal frame. However later on for the interior of the trailer you used spar varnish. Any reason you can think of why the Minwax spar varnish wouldn’t work in place of the epoxy on the wall edges? I figure they are both means to solving the same problem of waterproofing the wood.

    • That should work fine but it is not a permanent water barrier for external uses and might need to be reapplied in the future. Since most water intrusion would occur on the edge that shouldn’t be an issue to reapply if needed. Take a look at Thompson’s Waterseal instead, it is meant for this purpose and might be a better solution.

      The reason I used epoxy was that I knew I would never have to think about it again, also I had it laying around and was eager to test it out 🙂