The deck forms the foundation of the teardrop and consists of a poplar 1×4 (3/4″ x 3-1/2″) frame and 3/4″ hard white foam insulation sandwiched between 5′ x 5′ x 1/4″ birch plywood sheets.
It’s nice to have the trailer assembled to haul the wood around, but be careful not to damage it in the process.
I used pocket screws to attach the frame and check that everything is square before applying Titebond III wood glue.
Clamps, you will need lots of them for this project. This side being the eventual underside I used brad nails to hold the birch to the cross members so the glue would bind correctly. On the opposing side, which is the top of the deck and exposed on the inside of the cabin I only used weight. I cut the birch sheet to size using a straight edge and a circular saw.
The insulation is 3/4″ hard foam and fit very well leaving only 1/8″ between the top and bottom sheets. I cut the insulation to be 1/8″ larger in width and length than the frame compartment which allowed us to get a nice tight fit. I cut it on the table saw but a straightedge and a utility knife works fine too.
The opposite side showing the weighted objects instead of the brad nails to hold the birch to the frame while the glue is drying.
The birch skins had a very slight overlap so I fixed that using a router and a flush trim bit.