Tempe, Arizona
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Armadillo Tile & Design Tempe, Arizona
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Trailer frame Steel structure Structure paint Sub floor Roof frame Roof covering Exterior Scrollwork Exterior Wood Siding Interior wood panel Exterior trim Exterior paint Exterior trim paint Interior furniture Interior cabinets Ice chest Stove Porch Trailer paint Trailer lights Flooring Electrical Interior wall cover Bed frame Stairs Utilities Axles/Suspension Tag & License
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Some next steps:
  
 This months progress:
July Back from a couple of weeks of traveling. Arizona temperatures are still 110 but the first morning back, I was able to complete the wallpaper. Direct from England and sitting in attics for 30 years, traveling from pillar to post, it looks like it belongs. Painting is also complete, a light yellow as seen in the latest pictures. Ill just need to touchup the benches and counter prior to putting the floor down. Time also to source the slats for the bed and the mattress from Ikea. Painting the exterior detail will wait. I need to get it on the road and the detail can be done anytime. History Inspiration - This came about from a photograph of my dear wife Cassilda (aka, St. Casilda), standing in front of a vardo in a wooded forest near Sandy-Balls, England. My standard comment. "I can build that", which has gotten me into trouble before, was seized upon and the garage will never be the same for a long time. I found the preeminent, authoritative book on gypsy caravans in Australia, The English Gypsy Caravan, by Ward-Jackson & Harvey, that not only provides exquisite description, but larger then life drawings on which to pattern size and detail after, that will hopefully make it look like I knew what I was doing when finished. Method - Size does matter when you have to figure out how to build a vardo in a two car garage, yet still stay true to an authentic size and style, minus the waggon wheels. As I don't have horses, nor even if if I did, they wouldn't be able to pull a vardo 55 mph along the Arizona highways. I'm approaching this little dilemma by planning the near authentic construction, to be set upon a tandem axle trailer with license, lights, brakes and safety chains to keep me out of trouble with the local constables. It'll have to be built in stages, assembled then disassembled to move to the next one. The garage is crowded, I build other ornamental pieces and furniture there as well. It probably wouldn't set to well with a fire marshal, but I have separate areas for everything. Planning - I spent several months drafting the design in CADD, a terrific tool to overlay siding, furniture, trim and trailer to get initially close to a final configuration. Since I've never built a vardo, the drawing detail can be updated as I progress, documenting final dimensions and nuance for posterity. CADD is valuable for trying different materials before you buy them to adjust weight to cost ratios before the $$ spent. I'd like to end up with a complete set of drawings and details in case it needs to be duplicated for some reason. Materials - Knowing that in order to copy all the carvings and accouterments to have an authentic looking waggon, the selection and attachment of those features need to be solidly attached and become 'one with the waggon' so I wouldn't need Mr Peabody's sweeper following me down the highway gathering up the pieces. The alternative would be an earthquake proof design that allows flex and movement but still remains whole, which I have no idea where to start, even if it were possible. Since the trailer would be steel, it makes sense to have the frame as such, with a unique method for attaching the wood siding. Weight would be an issue but CADD lends well to determining heaviness and position of center of gravity, as the design develops. Metal vs wood? Tough decision. Wood is my material of choice. I've seen some great wooden vardos on the net using really good methods and design. My intension for this project is that it be authentic the best I can interpret, useful in a 21 century environment and also enduring. A possible heirloom, work of art, monument. A steel frame lends itself to rigidity that the wood siding can bond too, limiting road vibration. The walls can be thinner without loss of stiffness. Little material waste as I can weld the short pieces together or use in a different project etc, etc, etc. Weight is controlled through CADD, adjusting design concepts before applying. And the assembly in a small garage space can be modular, fitting whole pieces then taking apart to be assembled outside. Progress: Its slow, no doubt about it. I'd love to build this in a larger area and just roll it out to a renaissance festival somewhere. Extra steps are needed that wouldn't otherwise be there and when you add in working at a day job, football, honey do's and other habits, I'm probably not doing to bad in the 7 months I've been on it. I've been thinking about other ways to use it other then just a unique camper. Got some ideas to develop more, that also fits into the retirement plan # 6.
June As I get closer to finishing, I realize it may never really be finished. Certainly the painting is tedious and with such a large canvas, I could always think of more to add or another way to do it. If I was experienced with building these as the old masters had. Maybe Id have a finished product in mind, where when I reach it, I can say Im done. Alas, Im not the type! Having nearly completed the bed, the interior is coming alive. The windows have most of the weather stripping and Ive started putting on the fittings. I used Lexan for the glazing and since its started to get >100deg in Arizona, the panes buckle out but don't break. 250 times stronger then glass! I keep a fan on in the garage to help out. The inquiries on the build are starting to pick up. Several folks wanting to rent it out, several more just wanting to talk. On track to have it on the road this year. It will be a splendid day when I pull it out and complete the assembly in the alley. Good excuse for a block party. May I think painting takes as long as building does. One year ago I was starting the reassembly. Anyone that has built a guitar or any fine wooden instrument knows there is little room for error. Actual perfection (if it exists) is a goal you either achieve, or convince yourself you did. Im sure I could build a vardo with exactness of a classical guitar given the time to do it, but Id like to take this creation out someday, not be buried in it, uncompleted. Thus I look with discretion at my workmanship and see less then instrument perfect result. The T111 is a great material to simulate the pennywood slats but isnt stain grade and does 'move' and allow its grain to expand. I suspect Ill have some regular maintenance to do on the exterior although I used the best paints and methods available. My goal to build with authenticity, alas, comes with selection of materials that meet a budget and timeframe expectation. The use of redwood where weight and stability is important is a good choice. The 1900s vardos didn't have to consider modern highway speeds. We'll enjoy it anyway. We have a lot of plans for it.
April What a month! Lots of family stuff going on but generally a good time. A visit to the New Orleans Jazz Festival was the icing on the cake. Got to see Feliciano after all these years after seeing him on Ed Sullivan back in the 60's. Oh, back to the vardo. Got most of the ceiling done except for a bit of trim. Found some awesome deco's for over the doors that fit the eastern motif that keeps sneaking in. I think I still will be under 3k lb's once I'm done but need to catch up on the table. The wifie is taking over now that were into the the interior colors and decoration (at least I wont have to move furniture). After 2 years I can almost smell it. May have to fly my son in from Florida to help me with putting the roof and axles on. The next major stage is building the frame for the roof to wheel out of the garage. BTW, getting closer on the guitar. Finally finished the french polish and ready for final assembly.
March Amazing how adding a few windows seems to make it look like Im almost finished. I do feel an expedited pace developing. The window seal should work perfectly against the wind and rain, but in Arizona, not much of the latter. One side of the cabinets are almost done. selecting the right quarter sawn wood for the bench took several visits and a few returns to get right. The trim around the windows is as far as I can go until the roof is permanently attached. Decided to put the sink on the other side next to the door. A little closet for it can be decorated with a mirror and small shelving. Once the cabinets are done the wallpaper commences and then the paint. An oh yes, the ceiling. Elephants on the rampage!
February The detail painting on the wings is slow going. The color selection is difficult, as what I see in the paint store doesn't necessarily work on the finish product. All the ceiling panels are complete and ready to go up. Next month should see the ceiling in and trimmed in the gold edging and ready for the wallpaper to go up. Still trying to make the roof as lite as possible for the eventual hanging from the garage roof, to the rolling out to place on top of the finished vardo. No lack of commitment in site, working on it most everyday for the last 20 months but the detail will take the most effort. ~40 tiles are complete. Need to go get some more slip to finish the rest and make some insets to the upper wall. Ive found some nice scrolls for the lower wall that should dress up and fill in the voids.
January 2010 The detail of the painting has set in and time it takes to do it. Painstaking work with minimum effort but as important as all the other work up to now. The colors are all mostly selected but still have to decide on how much detail goes into the 'floral' part. Im not skilled at freehand but can learn I suppose. Ill hang the first window today with any luck and follow up with locks and weather stripping as I find the right ones. The back porch is assembling nicely and really adds to the authenticity. Almost have all the wood cutting complete so I can clean the garage and keep it that way. The tile takes a while to do so I made another mold to speed thing up. Ill maybe do a firing today, Ive figured out how to fasten these to the wall so Ill have some pictures by the next update. December 2009 Holidays are upon us and time for some reflection. A little over 18 months, working almost daily on the caravan. Design, materials, procuring, cutting and assembly, thinking I could do it inside a year until life got in the way. Taking an original picture 25 years old and applying an original concept to vardo building has taken no toll that hasn't evolved into an labor of love and meaning. The window/door addition will be the threshold where light is indeed at the end of the tunnel. Painting detail has started, wallpaper purchased in England is down from the attic and will do nicely. We also found the perfect ceiling cover (elephants no less) at a cloth store in Phoenix. An English vardo with a Buddhist Thai influence! No doubt one of a kind.
November 2009 The turkeys eaten and the relatives are gone, its time to get back in the garage. Actually a bit of progress. I think the hardest part has been with the painting, trying to get the right color schemes a matches from the local paint store thats still trying to learn how to work their computer. The next color is the green, gold and light almond to get but these should be easier then the reds have been. We'll make a trip to the cloth store for the ceiling covering this week. I imagine more frustration as Ill be with the gypsy wife who has her own ideas. But thats OK with me. Since painting is the fill-in, the windows and door is next, already built just waiting for the 'glass' and routing. Trying to finish up some other projects around here has slowed me down. The guitar is ready to finish with the frets being done and shelves in the kitchen have been 3 months in the making. Its my curse. The whole roof design was a work in progress. It needed to be light but stable in highway winds. The Arizona climate is brutal with expansion/contraction a concern sometimes changing 40d in 12 hours. We shall see. October 2009 Returned from 3 indescribable weeks in Scotland with new vigor and a few ideas. Only saw 1 vardo parked as an empty relic in front of a castle, like some proud race horse put to pasture. Probably used as a sheep waggon which requires swinging only one dead cat to hit one. Scotland has to be seen to be believed. Ive adjusted my schedule since being back, it's cooler now in Arizona so I'm staying off the internet, except for research activities, waking at 3am to do some painting and quiet work on the vardo and guitar, before heading to the 'real job' that funds this endeavor. Tea instead of coffee (Im almost through the withdrawals) and completing my reading on Scottish history. No news, no politics, no invasions of mental privacy that I avoided while away. Cassilda lives in the 18th century, why shouldn't I? With the painting started, Im seeing the end after 16 months. Changing the roof attachment from a weld to a combination 'monkey glue'/modified c-clamp will prevent damage later and allow me to complete all the interior finishes without risk. I found a large Camino shell in Scotland for the front emblem but sadly the Red Stag antler set was confiscated in Edinburgh. To many hijacked planes with antlers I suppose. I laughed after the crying stopped. Time and opportunity are the only things preventing completion, the big $$s spent and the journey continues.
September 2009 I have reached a new phase of sorts and its been a while since Ive updated. All the work to now has been to build the vardo with the intent of taking it back apart once the trailer is licensed. It had to do with not having to pay the $25 a month storage fee at the HOA parking area. Its a shame to think a vardo is considered an RV, just doesnt seem right. Building this has been a journey. Initially thinking I could finish it in no time but one year later, I still have far to go. Ive kept track of cost, material, design and other 'opportunities' that should be better documented. Although building one is nothing new, this vardo is unique in construction and maybe someone out there has the time and skills not just to build one like it, but to improve upon. So Ill need to upgrade this site format with some other information. Not a blog, I don't have the energy to do that well, but more information on the construction and methods. I'm sure there's folks out there that have followed this over the last year that first impression was 'what the hell is he doing!', Well I have to admit I sometimes wondered that myself. Most of the corners I backed myself into have offered new challenges or helped me see a better way. This would have been more of a slam dunk if it weren't for the fact I was building an 11 ft high vardo that had to eventually move out of an 82" garage door. Im trying out another concept for the flower carvings. I have the pottery studio and If I can make them from clay instead of wood while keeping the weight down, that will go much faster and provide a unique decoration once they are fired. Making the molds is the first step. There may need to be more then one as Ill need about 120! We shall see. The paint colors been picked and Ive got one side ready for primer. July 2009 The marriage of old world vardo architecture and the use of the poly sheeting for the roof skin is certainly a challenge. From the beginning I believe it will work fine as I have Arizona experience with it and its really a fine product. Lifetime warranty, wont tear, break, discolor, etc and I think the long lines will complement the wood siding groves. If you've been following this build, you may have noticed that much of what Im doing is mostly R&D in applying current materials to look like an authentic vardo, but perform better due to the AZ environment and road conditions. Would I have done things different? Maybe. One concern I have is the upward pressure lift on the fasteners from inside the vardo while traveling. I doubt Id be able to completely seal the walls, doors, windows and cracks allowing air in but Ill do some skin pressure reading later on to see what's the best formula for having windows open or not, while traveling. The intent was to keep the center of gravity low due to the 'boxiness' of the vardo and poor aerodynamics. Finally, the frame is going back together and the first piece of siding is attached. Thanks to modern technology, the glue Im using will attach and expand to fill any gaps between the siding brace and the frame member. A strategically place screw sets it all in place until the glue sets. All structure vibration seems to be gone with the roof setting on the frame. Total weight should still be under 3000# loaded but Ill confirm as I need to update the weight table.
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