Aluminium Caravan Question

Hi All,

I have been toying with the idea of building a small light weight camping caravan.

The idea has been developing in my mind for the last decade or more, and revolves around the stagnant designs that I see in caravans currently. Effectively, they are boxes on wheels and heavy. Many years ago we had a small Topagee which had two (2) double beds, hard top and when loaded with water weighed in at 420 Kg. We used this for 4x4 (Wonnangatta, Fraser Island, Kangaroo Island etc) for our family of four (4). It was light enough to be dragged over any obstacle.

Recently I have noticed some European caravans have an Aluminium frame construction (drawbar) - so it can be done. Whilst I realise that 4x4 driving is much more demanding than bitumen driving, with a lower weight component, it may be feasible.

To that end I would like to build a circa 1:1.5 scale model to prove (or disprove) the concept.

So I have a couple of questions for the brainstrust of the forum as follows:

1. How can a traditional steel coupling be attached to an Aluminium drawbar?
2. The same question applies for the suspension system, or can Titanium be used inlieu of steel components? Corrosion between two (2) dis-similar metals is the concern here.
3. In mocking up a scale model (and as I am lousy at Aluminium welding) is there any suitable glue that can be used to bond Aluminium to Aluminium?
4. What grade Aluminium section and sheet should be used?

Thanks All.

George


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