instructables

Gypsy Wagon Construction

by GeorgianBay Scott

the georgian vardo ( Sold ... another vardo build in progress For the most recent adds and modifications refer to
)
steps 8, 9 and 10.
.
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Updated : August 15, 2015 ...... Finished pictures
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posted under step 10
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Introduction

I am posting a photographic journal documenting my

About a year and a half ago I discovered a gypsy
progress as I build a gypsy wagon. I have named her,
wagon several kilometres from home while on a walk.
the 'Georgian Vardo'. The pictures have been
Forgotten and a little worse for wear, it was parked in
grouped into nine steps of construction and one page
the backyard of a home, being used to store unused
of materials. The dimensions can be found under step
garden tools and flower pots. There was something
11. As of August 15, 2015, the georgian vardo is
about it and the dozens of vardo pictures I discovered
essentially complete. Construction time was just over
online that held my fascination as a woodworker and
3 months, working on it in my spare time and on most
wood artist. It was rustic art on wheels. Unlike the
weekends.
beat-up discovery down the road, I now understand
that historically, gypsy wagons, caravans or vardos
I have no 'detailed' plans for building a vardo. Usually
were four-wheeled horse drawn living wagons. They
I design as I build. As with any project I take on, the
were often intricately carved and vividly decorated.
inclusion of creativity or whimsical craftsmanship is a
When I first saw one several months ago I was
must. The same has been true with the construction
amazed at the detail and artistry that the builder had
of the gypsy wagon.
put into her wagon creation. Now there was a
backyard woodworking project! It had all the elements
Although the interior construction of the wagon is
that attracted me to do the same. And so I decided “I
pretty well complete at this point, it needs decorating
am going to build me one of those”.
and some whimsical touches. Feel free to make
suggestions in this area as my spouse will argue I
Gypsy wagons can be grouped into different styles
have zero decorating skills. Readers will probably
including the Brush wagon, Reading, Ledge, Bow
understand the construction steps from the pictures
Top, Open lot and Burton wagon. I think I like the
(many with instructional comments) and, although
Reading and Ledge style the best. Perhaps I could
sequentially posted, you can feel free to contact me if
combine the two styles and use a recycled two
a step is not clear. Some additional details and a few
wheeled utility trailer as the vardo base frame. I
more pictures can be found at
decided I would build a wagon built on a 4¢ X 8¢ trailer
https://georgianvardo.wordpress.com/
Gypsy Wagon Construction: Page 1
frame, remembering that the teardrop I rebuilt last
year had an interior space of just under 4¢ X 6¢.
Adding the ledges would give me 6¢ X 8¢, double the
interior compared to the teardrop and more than big
enough for a tiny wagon. Besides it would be easier
to move around both while building and later when
positioning at a campsite.

Using Kijiji, I located a well used but solid utility trailer

with a heavy duty frame, axle and tongue jack that
met my requirements. And it was cheap. I began
construction in late April, planning on a 6 - 8 week
build. As of today (August 9, 2015) I have about 90%
of the exterior completed and inside I have completed
a single couch / bed that extends to double bed
(gaucho style). Will be adding a few more curly
brackets, colourful trim, some shelving, an exterior
lamp outside the door and perhaps a kitchen galley
box. Will try to keep the picture gallery updated until
the vardo is completed. By the way, it would be great
to meet other local gypsy wagon builders. Feel free to
contact me.

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Step 1: Materials and Tools

Materials and Tools One used 8 x 4' utility trailer

The material list is from memory and the exact Polyurethane, stains and paint
quantities have not been recorded. This is most of it
though. 4 gate hinges and 1 gate latch

MATERIALS: several pieces of embossed pine moulding ( 8'

lengths)
50+ 6’ tongue and groove 3/4 x 5" pine boards
several pieces of aluminum trim ( 8' lengths)
10+ 8' tongue and groove 3/4 x 5" pine boards
-----------------------------------------------------------------
2X2's for framing walls (I used finger joint kiln dried
spruce) Tools:

5 knotty cedar 8' 2x4’s for ceiling rafters
a few 8' 1x4's for door and window trim
2 8’ 5/4”x12 pine for ledge brackets
a gazillion feet of 5 foot cedar fence boards, ripped to
2” and a few to 2.75” for battens and corner trim
1 sheet 3/8 ply, 1 sheet ½ “ ply and 5 8’ PT deck
boards (5/4”) all for the floor
I worked with dimensional lumber where possible so
there would be no need for planing.
Table saw, mitre saw, handsaw and hack saw
Carpenters square, speed square and adjustable
bevel square
Hammer, screw drivers
Impact driver, drill and various bits

Construction adhesive and exterior wood glue Hand plane and jack plane

Small box of 2.5” self drilling screws for fastening Tape measures and pencils
floor to steel frame
Several ratcheting bar clamps (short and long)
Box each of 1.5", 2” and 3” deck screws
Pair of saw horses with a sheet of plywood
Box of 1.5” roofing screws with neoprene gaskets
A random orbital sander
3 or 4 windows and an old door from the Restore
(local used construction materials) – 4 windows and 1 Jig saw or scroll saw ( I used my band saw for all the
door cost me $30 total brackets)

3 sheets (4' X 8") of mahogany veneer ¼” ply for Paint brushes and sand paper
inside ceiling

3 sheets of galvalume steel roofing

Gypsy Wagon Construction: Page 3

Step 2: Begin by Building the Basic Box

I began with purchasing a used, heavy duty utility
trailer. The wood floor and side walls needed to be
replaced but otherwise it was solid and the right price
for my project. If the frame needed any modification
or strengthening, this would be the time to do it.
5/4" PT deck boards and a top sheet of 1/2" ply. The
road side of the bottom sheet was given 2 coats of
exterior stain before laying it down. The deck boards
were screwed to the steel frame using self drilling
screws.

The floor was built as a 'sandwich' from 3/8" ply, then

Gypsy Wagon Construction: Page 4

Step 3: Building and Raising the Walls

The two side walls were built on the ground and lifted into position. The top and bottom plates were bevel cut at 7
degrees so that they would angle out from the ledge. This bevel cut was done before attaching the vertical boards
(wall studs).Actually, this step was by far the quickest & easiest part of the construction.

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Step 4: Adding the Siding

This was quite time consuming at first, making certain that each course was level to the board on the opposite side
of the door. None the less quite satisfying to see the walls go up and for the wagon to start taking shape.

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Step 5: Building the Roof

The basic idea I had here was to run three cedar 2X4's from front to back. They would sit on and be attached to a
'bench' above the door and the end window. I bevel cut the 1st and 3rd beam. The top of each wall was previously
bevelled so now there would be 5 beams to bend a sheet of thin (1/4") ply over the beams and following the curve
of the top of the wall. The whole structure was amazingly strong once it was all connected.

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Step 6: A Few Exterior Details

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Step 7: Roof Trim

A work in progress. Ends are weather sealed. Decided to add a couple of decorative brackets at the door end,
outside wall between the ceiling and wall. Those are trivets at the top of the door frame.

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Step 8: Trim, Door and Paint, Paint and More Paint

I used a good quality exterior latex paint with built in primer. Two coats. Cut all the brackets using a band saw.

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Step 9: Gaucho Bed

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Step 10: Finishing Touches

I think I am done. Now for the fun part. A second road test tomorrow and then a few small camping adventures at
nearby campgrounds. Most of my friends think I have lost it and are shaking their heads. Oh well, I built it for me.

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Step 11: Dimensions
Vardo Dimensions
The used utility trailer I found was roughly 4’ X 8’with
14” wheels. With the original weathered wood
removed, the inside of the trailer frame measured 50”
X 98”. This caused a bit of a problem initially, but I
built it to accommodate 8 foot plywood for the floor
and side walls.
· Box width = 4’
· Box length = 8’
· Ledges = 12”
· Length of sleeping bed frame = 74”
· Width of sleeping bed frame = 48”
· Walls = 46” along the hypotenuse
· Wall angle = 7 degrees
· Distance along arc of roof 96”
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· Height from floor to midpoint of roof = 80”
· Door height = 72”
· Weight (estimated) 1000 lbs. Tongue weight (not
known)
See my rough drawing plan. Pretty well went with the
look and shape but redesigned as I went. Dimensions
above are accurate.
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Currently I am completing a number of modifications
to a new teardrop camper that readers may be
interested in seeing. Some of the mods and add-ons
should work with other models of campers.
https://www.instructables.com/id/Thirteen-Teardrop-
Camper-Modifications/
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 Hi Scott. I'm admiring your work...and trying to steal ideas for my first build! I have my walls framed
and I'm looking to start the roof. I'm hung up on the arch. How did your friend calculate the arch of
that template?
Cheers
It was her idea but here is how I adapted
it. On a sheet of ¼ inch plywood that is at least a foot wider than the vardo,
draw a series of arcs, varying in height but having exactly the same width of
the top of the wall. Then tack the sheet
to the wall, stand back and pick the arc that you prefer. I chose one that was
approximately 18” higher than the top of the wall. Your choice. Now cut out the sheet along the
chosen arc
using a jigsaw, re-attach to the end wall and nail or screw the remaining wallboards
temporarily. Using the plywood template as your pattern, draw the arc onto the
top boards, then remove the template and top end boards, cut the curves and
reattach. This is more difficult to write than to actually do. Hope this makes
sense, and good luck with your project.
like Tinkerlady and Jay, I love the style though like most people I want to do it a little different. A
few months ago I dumpster dove and came home with about 26 triple pane plexiglass windows
that are about 5'x5', with the outer pane being opaque. I'm planning on using a couple to form a V
in the front to cut down on wind resistance and also allow the light to shine through. I've got some
more ideas I want to build into it but it would take to long here.
One question , how did you seal up the roof so that the front wouldn't leak?
Short answer, lots of caulking. I ran a thick bead of caulking around the top of the wall before
attaching the the roofing which over hangs by 4 inches at the front. Then caulked again on the
Gypsy Wagon Construction: Page 22
 outside after the roof was secured. The ran a piece of trim on the outside all around with another
bead of caulking under that. The three layer roof was sealed on all edges using ice and water
shield before attaching the eave. I think the pictures in the steps show each of these details. Good
luck with your project.
A few of you have inquired about the weight and I can only estimate as I have not taken it to a
scale. Using an approximate weight for the number of square feet of lumber used, and then adding
in 100 lbs for fasteners and the roofing, I would think the total weight (not including the trailer frame
itself) would be between 750 and 900 lbs.
Great job! I was planning on building a teardrop but this project is making me think twice.

Thanks. I have built both. I'm in the process of steampunking the teardrop that I restored last year.
Lots of copper pipe, brass, taps, guages and retro whimsy. Will post a short instructable soon.
I absolutely have to do this! Fantastic work!

This is just brilliant. The trim details are so perfect. A genuine work of art. How about some faux
wooden spoke wheel hubcaps? I know you'll enjoy every moment spent in your 'georgian vardo'.
Great work!
I agree with tinkerlady. This is brilliant, and I too want one. Some better day, perhaps when I have
a little more time.
Brilliant. I am amazed, and I want one. This looks like an awesome place to hang out and draw
inspiration for more projects. Well done!!!
Well thank you tinkerlady. And you are correct about the inspiration. Decided last evening that it
needed some homey comfort decorations ( gypsy style of course). Perhaps my daughter will
advise. I will post an update in a couple of weeks.
love it
Love it.
love it

Thank you. So do I. First camp adventure with the vardo next weekend.

Love it hope I can do the same very soon.

Thank you. Since retiring a few years ago, outdoor projects, woodworking and a return to camping
has been most enjoyable. In fact I was working on the interior of the vardo when your msg arrived.
Enjoy your wagon building once you get started and be sure to post some pictures. Cheers from
Ontario, Scott
If you have any more pictures of the process, it would really help people follow what you did.

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