THE LAST BARAVAN - 2020
Hi all,
In September 2020, Bruce Barrett provided us with a detailed history of the Baravan caravans built by his father, David Barrett. The history can be found in the first post on this thread here, and a guide to the body styles used by Baravan from 1954 through to 1978 can be found here. When Bruce provided us with the history, he told us that he was in the process of building a new caravan which would be the 'last Baravan'.
Bruce has now provided us with the story of his van, which is set out below. The last Baravan is Bruce's vision of what a Baravan would have looked like if they were still being built in 2020.
As most people will be aware this Forum is focused on Vintage caravans, that is caravans built before 1970. Over the years we have largely restricted posts to those about Vintage era vans, although we have accepted some posts about caravans built later than 1969 if there is a link to the Vintage era, or someone has built a retro caravan in a Vintage style. This post is one of those exceptions because it tells the last instalment in the Baravan story - a fitting bookend to the Baravan chronicle if you like.
Thanks to Bruce for being willing to share the story of his caravan. And many happy travels.
Don Ricardo
BUILDING THE LAST BARAVAN CARAVAN
A journey for Bruce Barrett.
In 2019 Jenny and I were holidaying in the South West of WA and discussing our caravanning future for the next 10 years with our current caravan. We thought of all the things we would like and created a bit of a wish list. I suggested it would be great to have an old Baravan with all of these features though not really giving it a great deal of forethought however anything is possible.
There were no previous Baravans that came anywhere close to our requirements and I suggested since I am now retired why not build one…….anyway here is the journey for me that was initially started by my father in 1954.
Sourcing materials and drawing the design, shapes and components on computer using AutoCad was the first step. Every item was drawn to the millimetre to ensure everything fitted together on paper and finally in October 2019 the assembly process started with practical completion and licenced in December 2020.
Chassis Information:
Body size 20ft x 8ft
Main chassis frame 100 x 50 RHS with 50 x 50 SHS under packer.
Front and Rear 100 x 50 RHS
A Frame 100 x 50 RHS with 50 x 4 flat vertical reinforcing
Interim flooring supports 50 x 50 SHS
Side frames 20 x 20 x 1.6 SHS
Springs Rocker Roller type 60 x 7 spring leaves
RHS – 9 leaf LHS - 8 leaf
Axles 50mm square
Brakes 12 x 2 Alko Electric
Wheels 18 x 8 Landcruiser 2013/2015 model
Water tanks 3 @ 90 litre
Grey water tank 50 litre
Coupling fixed 3500kg.
Spare wheel 1 on rear bumper
Computer designs.
These were the base drawings from which all components were drawn.
The caravan was to be built in a unit in Myaree and occupied an area of 8 mtr x 3 mtr with the same area alongside which was used for storage and preparation of components. The area was limiting so building had to be done in stages with the first being the chassis and steel framing.
Chassis and FramingWhere possible I ordered the steel to be cut to length which avoided having to cut each piece by hand.
2 steel trestles were made, squared up and set level for the chassis to be built on:
Steel and chassis components set out to start welding the chassis:
The chassis was welded upside down starting with the longitudinal rails and front and rear cross members:
Square up chassis and set A frame in place:
Chassis steelwork welded, welds painted and springs, jack leg brackets, water bolts located in place:
Chassis now turned over. Ready to fit axles, wheels etc and water tanks:
The chassis was used as a base to make the side frames. The first one was made and tack welded to the chassis then used as a jig for the other side:
The first side frame clamped and squared up to the chassis before welding to the outriggers of the chassis:
Repeated process for the other side and ensured width was true side to side then used steel cross bracing to square up the sides to the chassis. Next step started fitting the front cross rails and roof rails:
Caravan turned around to fit of the rear and remaining roof rails:
Completed steelwork:
Building the Shower.
Materials used:
Pine plywood 3mm
42 x 19 Meranti timber
12mm ply for base
Polyester resin and Fibreglass matt
Firstly a pattern was made for the side profile of the shape of the rear of the caravan:
Then the shower cubical was made similar to a cupboard.
2 coats of clear polyester resin and fibreglass cloth applied to walls and floor then 2 coats of white gelcoat applied with a roller. White plywood finish to the door opening, trimmed with aluminium angle and 10mm thick clear acrylic supported on clamp hinges:
Hudson helping out keeping the floor clean before the lino was laid, and Danielle helping out with the shower double checking shape and measurements prior to fitting:
After fitting the plywood to both walls the rear sheets were fitted around the shape, needed 2 sets of hands so Jenny helped out with the bending and pop-riveting to the rear framework.
We fitted several roof sheets to the ensuite area the shower was lifted into place then fitted the rear partition wall:
The remaining roof sheets and front I managed to do on my own with a simple framework to hold the sheets close to the roof, slide into side extrusions, clamp in place then pop rivet:
Bed made and fitted, meranti framework glued to plywood and bolted to floor:
Furniture
White 15mm plywood.
I had drawn all of the furniture components with AutoCad so they could be downloaded to a computer on a CNC machine. Each sheet had the components laid out in order to minimize waste.
There was not enough room to store (at Myaree) all of the components cut at the same time so I had to plan how many furniture cupboards could be assembled and stored in the small area then reorder the next patch once the previous batch had been fitted inside the caravan.
CNC cut panels:
Ensuite overhead cupboard and lower cupboard assembled:
Ensuite cupboards, toilet and washing machine fitted to rear of caravan:
Rear partition and sliding door fitted and dinette seating in place:
Lower kitchen cupboards and refrigerator cupboard:
Help from Jim to fit the kitchen overhead cupboards and lower kitchen cupboards:
Bedroom cupboards in place. The robe and the dressing tables were built in 2 pieces then slid into place to match the curvature of the roof:
Electrical cables internally to met in 1 common place – cables everywhere – 12 volt, 240 volt, speaker and coaxial:
First sheet of aluminium to door side – starting from top then working down. Polystyrene insulation fitted into wall cavities and around electrical cables:
Drivers side showing insulation, electrical and fixing blocks before fitting aluminium sheeting:
Door side with aluminium sheeting fitted:
Jim helping out again fitting aluminium sheeting – first sheet fitted:
Plumbing to vanity and washing machine:
Plumbing to holding tank and rear of caravan:
Roof before insulation and aluminium sheeting:
Finishing off the rear of the caravan:
Front of the caravan insulation and aluminium sheeting:
Roof accessories – hatches, scupper vents, airconditioner, solar panels, ensuite hatches and 12 volt satellite dish:
Front of caravan finished:
Interior from front – kitchen, dinette, ensuite:
Interior – dinette:
Interior – Ensuite:
On the road to get the caravan weighed then licenced:
Visit to mum:
On the road for our first trip to Yallingup:
