Select a viable trailer plan. There are many travel trailer plans available on the Internet, some costing money, and some downloadable for free. Often, the free plans are actually scans from magazines of the 1930s and '40s, the teardrop trailer's heyday. They are as applicable today as they were then, but, because of inflation, the pricing of the listed materials is no longer applicable. Free travel trailer plans are available online (see Resources 2), while other sites offer modern, updated travel trailer plans for a price (see Resources 3, 4 and 5).
Purchase the required materials. The wheels, rims and axles pose the largest potential cost; they require removal from a small car. You can cut down enormously on this cost by going to a junkyard and purchasing a scrapped, but intact, car body. You may be able to find the iron pieces as well, thus eliminating all the major costs of assembly.
Assemble the teardrop travel trailer according to plan. You can do this in several ways, depending on your technical prowess. For those without substantial welding/carpentry skills, consider having a mill cut the side windows and door and having a welder fuse together the iron pieces. This may add to the overall cost of assembly but is necessary for both your well-being and the well-being of the trailer-to-be. If, on the other hand, you are competent with the necessary tools, you can complete the tasks with a jigsaw, a band saw and a welding gun. Though they may not be cheap, it is still more cost-effective to purchase them than to outsource the work to professional craftsmen.
Hitch the trailer up to any car you please and start traveling. One of the best aspects of DIY travel trailers is that, unlike their dealership-bought counterparts, they are extraordinarily light, turning any family vehicle into an RV fit for the countryside.
