Our target is to have the Teal Camper available in early summer 2010. The prototype is finished and the final design is nearing completion. Our task now is to make the final arrangements for manufacturing and distribution.
Putting the design and prototype together has not only been a learning experience, but enjoyable as well. It has met or exceeded our expectations on every level so far.
The prototype is built for a 4' x 8' utility trailer. It is absolutely amazing how much you can get on a 4' x 8' piece of plywood. because of the flared out design, the inside dimensions are 5' by almost 9'. That gives ample room for sitting four at a table and sleeping two in a full size bed. It also allows room for standing, cabinets and even a small kitchen.
The popup top makes the camper feel roomy. Tilt out windows in the body panels and screened zippered panels in the popup top provide that all important ventilation.
Best of all, the prototype camper weighs in at only 220 pounds. On my utility trailer, the whole thing ends up about 550 pounds. That is well within the limits of the 1000 pound towing capacity of my little Chevy HHR.
I look forward to getting your comments on the Teal Camper.
The weather in Colorado is finally giving us a break. We will be able to do some serious road testing of the prototype. We want to have as many issues identified and resolved as we can before we commit to a production prototype.
What a great looking design! I hope your production plans proceed smoothly and on schedule. The largest version interests me the most. Do you have any idea about the price point for these? What is the interior height without popping the top up?
Posts: 1 | Your City and State: Tulsa area | Registered: 17 March 2010
The interior height of the Teal Camper without popping the top is 5'. There will be an option available for those who don't want the popup.
As far as pricing, we only have a target ballpark at this time since we are still getting bids from component suppliers. Ordering will be done shopping cart style where you build your camper online to your specifications.
A Teal Camper for a 4'x 8' utility trailer (5' x 8.5' interior), outfitted as shown in the assembly video, is targeted between $3,500 and $4,000. No promises at this time, but that is what we are shooting for.
While work progresses on getting the camper shell components manufactured, a revised pop-up top is being developed. The new pop-up will have a hard top with fewer parts, easier to assemble and easier to operate. Pop-up height will be 6'-2".
There will also be the option to choose a hard top without the pop-up. This was actually in the initial design because, for the most part, you are either sitting or sleeping in the camper. Interior height is approximately 5'. It would give more headroom than a tear drop and allow sitting at a table without the complexity or cost of a pop-up.
Either way, it will be part of the customizing feature of the Teal Camper kit.
PRODUCTION SCHEDULE NOW POSTED - Now you can follow our progress via a production schedule. I will keep it updated as progress is made. PRODUCTION SCHEDULE
Molding companies are getting busy again. That is a good sign for the economy, but it is putting the Teal Camper a bit behind schedule. Getting tools (molds) made is an eight week process before a single part is produced. We will continue to push our suppliers to deliver as quickly as possible, while at the same time making sure that the product produced is the best it can be.
Details...details...details. The molds are in process. We are told it will take 8 to 12 weeks to complete the molds. Once the molds are at the molding company, the molders will "season" the molds and run sample parts. When we receive the sample parts, we will assemble two campers, one to fit a 4x8 trailer bed, and one to fit a 5x10 trailer bed.
Of course all the other parts, like the pop-up roof, doors and frame, bench/table/bed, cabinets, etc., all have to come together at the same time as well.
We are still shooting for September for the first roll-out. It is an exciting time and we are all anxious to get the first production unit on a trailer.
The panel molds are finished and on their way to the rotomold facility. The first test parts will be run during the next two weeks. A production mockup will be assembled with these test parts and fixtures will be constructed for the foaming process.
It now appears that actual production is approximately one month away. A few final details need to be settled and then we will make field test units available to a select few. More about that later.
I anticipate that we should begin taking orders mid-October for delivery beginning in late November.
Setting up manufacturing is a complicated process involving the coordination and cooperation of a lot of entities and individuals. It has taken longer than anticipated, but the Teal Camper will definitely be ready for the 2011 camping season.
Yesterday was a benchmark day, the first side and corner panels were pulled from the molds. It was exciting to see a year's worth of work become reality. Although the first sample parts were not perfect, they were enthusiastically received.
The rotational molding process is not an exact science. Although the mold is perfect in shape, it takes a time of trial and error to get the optimum temperature, timing, wall thickness, etc. to perfect the final result. We were pleased with the initial results and look forward to the production parts.
While we are waiting for the fixtures to be fabricated that hold the parts to maintain their shape during the foaming process, we will run some hollow parts for testing assembly. The foaming fixtures require approximately four weeks to fabricate.
Progress is slower than we had hoped, but that seems to be typical in the product development arena. The good news is that we have just achieved a major milestone and are much closer to a finished product.
You can read more about this event on our home page news section.
Topic Closed
The molds are in process. We are told it will take 8 to 12 weeks to complete the molds. Once the molds are at the molding company, the molders will "season" the molds and run sample parts. When we receive the sample parts, we will assemble two campers, one to fit a 4x8 trailer bed, and one to fit a 5x10 trailer bed.