Building a Catio - Need ideas for portable screen enclosure

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heySkippy

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  • #1
    I want to construct a screened enclosure that our cats can use to get out of the camper, at least somewhat, and have a view of the area from a nice, elevated vantage. Here's what I've got to work with.

    On the inside, in our bedroom, there's a dresser with a window. The window is 32" by 22" and the cats already like sitting on the top of the dresser and looking out. It could be better for them, though, as there are often things (clothes & pocket stuff mostly) laying up there and it can be a bit cramped for both of them to use at once.
    IMG_3399.jpeg

    On the outside of the camper the bottom of the window is almost 9 feet off the ground.
    IMG_3397.jpeg

    What I've got in mind is a simple shelf on the outside of the camper, about 6" below the bottom of the window. It would be somewhere around 48" wide with the right side flush to the window frame and the left side extending 16" in that direction. The shelf and the window would be entirely enclosed by an aluminum screen box. Here's a list of some of the prerequisites that come to mind.

    • The shelf has to be sturdy enough to hold a combined 30-ish pounds of cats without fail.
    • The shelf needs to be weatherproof and preferably lightweight.
    • The screen enclosure has to be reasonably insect-resistant, so no gaps.
    • Make as few holes in the side of the camper as is reasonable.
    • Be able to assemble and disassemble and reassemble lots of times without it turning to crap.
    • When disassembled, it needs to pack "flat" for transportation.
    • The enclosure needs to be sturdy enough to not come apart accidentally if the cats push against it.

    For the shelf, I think a piece of 1/2" x 12" wide cellular PVC would be perfect. Something like this. I only need 4' of it, though. Not sure how I can source just that. It would have a couple triangle shaped legs and hang on the side of the camper using brackets/hangers/fasteners yet to be determined. This would, hopefully, be the only part that requires drilling holes in the camper.

    For the screens, simple DIY Home Depot aluminum frames. I've made these at home before, I'm pretty sure I can handle this part in my sleep. There would be a face screen that is 48" x 32" with a pair of side screens that are 12" x 32" and a roof screen that is 48" x 12". The shelf would be the bottom of the enclosure. For connecting the screens to each other to form the enclosure, and to hold it tight against the side of the camper, I am hoping I can use magnets.

    I've been looking at drawer and cabinet hardware and there is a wide variety of magnetic things available for cheap. I'm thinking that I could use them to stick the frame pieces together and also stick the frame to the side of the camper. I would use double-sided tape to attach the metal bits to the camper side.

    If it all works as I have it envisioned, once the catio is installed we could remove the inside screen. The cats could come and go as they please as long as the window is propped open. The screen enclosure would not impede the window's normal operation, so if we're leaving for a while or if we want to run the A/C, we can close the window and leave the catio in place. We carry a ladder, so attaching and removing the shelf and screens isn't difficult.

    My unanswered questions so far.
    • What bracket system to attach the shelf the camper (and also the legs to the shelf).
    • Details about the magnet system of holding everything together.

    I've go the screen materials on hand, so I'll start building them this week. Pictures, of course, will follow. Any suggestions would be welcomed.

    IMG_2734.jpeg
    Buddy & Maya say thanks. :)
     
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    Drizzt321

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  • #2
    I wouldn't fully rely on magnets, you'd need lots of pretty strong ones if the cats get to pulling/clawing or just climb the mesh with their full weight.

    I'd consider using a pop rivets & hinges perhaps, to put things together and fold them up flat. If you don't want to do that, I'd aim for rivet nuts and simple hand tightened bolts to hold it together, could do one per corner and probably be fine since it doesn't sound like it's very long.

    Or wait, are you talking about using window screens? I wouldn't hang any shelves off the mesh itself. And I'm not sure I'd trust it as a bottom to hold the weight of the cats, I'd make that out of something more solid.

    Maybe some toggle clamps to clamp one side to the awning post? Or drill through and use a bolt/clevis-pin/locking-pin to secure it at the top/bottom to that awning post.

    Or can you install a length of perforated strut channel or perforated 90-deg angle underneath near the edge? You can clamp/bolt to that to that to ensure a good hold and provide some more structural strength, perhaps. That seems to be near the front? Just make sure if you do you'll leave plenty of room for the edge of your truck for twisting/etc so it won't hit/jam on it and cause major issues.

    Probably also do a few of those shelves, use some artificial rope or something, stagger them, so the cats can climb up/down as they please, although you'd need a clip over the edge of the window frame possibly. Or you're talking about putting shelves on the side mesh as well? That'd all work better probably better, unless it's regular window mesh, no way that'd hold it up.

    If you do stick with the magnets, I'd avoid double-sided tape as the primary sticky thing, I doubt they'd hold up in weather well. E6000 or a epoxy cement of some kind that's weather rated.

    After re-reading through everything, sounds like you basically want a mesh box held against the side of your trailer, with 1 decent sized shelf as the bottom for the cats to enjoy?

    Maybe some 1" angle aluminum, bolt/rivet some chicken wire/fence/mesh to keep the cats in and strength to hang some things off of perhaps, and put some insect mesh over that to keep insects out. Hinge some parts, bolt some others so the box stays together. Bolt/clevis pin to that awning support, do a long flat/angle piece at an angle from the bottom to the other side to help keep it square-ish and together. Have a solid floor, which will also help keep things more square, and the cats can't fall through. Maybe cover in some cheap outdoor/industrial type "carpet" or "grass" or something they'll like sitting on more than bare plastic?
     
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    heySkippy

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  • #3
    Drizzt321 said:
    After re-reading through everything, sounds like you basically want a mesh box held against the side of your trailer, with 1 decent sized shelf as the bottom for the cats to enjoy?
    Click to expand...
    That's it exactly.

    Our cats are fairly sedate and have never shown any interest in escaping to the outdoors (and we've been in this camper since July) or climb screens. This will be a place for them to lounge. Being 9 feet off the ground I would wager they would skedaddle back into the camper if one of the panels came loose instead of jumping to the ground.

    I've already started building the panels using basic aluminum frames. I did get heavier "pet-resistant" screen although I'm kind of regretting that now as it's really difficult to roll a spline into. Still, getting it done.

    I'm coming to agree that magnets for holding the frame together aren't a good idea, but I'm still thinking that's what I'll use to hold the box to the side of the camper. It can be attached more firmly to the shelf, but I don't want to drill more holes in the camper than necessary. It'll be in a location that's easy to monitor. Home Depot sells little ring molybdenum magnets. Perhaps I could screw them to the aluminum frame and then glue steel washers to the side of the camper for them to hold. Maybe a thin weatherstrip along the edge of the frame with gaps for the magnets would seal it nicely.

    I did some looking again today and I think a wood shelf is the answer. A simple piece of 12x48 pine with exterior paint. Still don't know what kind of bracket to use for this. I would like something where the shelf slides down onto a pin or something with no tools required when putting the shelf up or taking it down.

    I'll finish the panels today and tape them all together for a test fit. Tomorrow I'll explore the shelf further.

    ETA - I just had a braingasm and realized if I want to hang a shelf, I should be looking at shelf brackets. I've been in the wrong department at Home Depot.
     
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    Drizzt321

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  • #4
    Gotcha.

    And yeah, bit of wood and exterior paint I'd think.

    Still disagree on double-sided tape for anything more than a basic test, since this is going to be outside.

    And yeah, some shelf brackets, possibly held on by bolt + wing nut through the side of the frame? That could actually be part of holding the sides and side away from the trailer even.
     
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    heySkippy

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  • #5
    So, here's where I'm at. I only got one screen put in, that pet-proof stuff is a bitch! I swore when we sold our house that I would never spline another screen, and here I am. ;) Now it's raining and supposed to only be in the low 60s tomorrow, so it might be Friday before I resume.

    I'm not putting on long pants to do this...

    Anyway, this is where I'm at.
    IMG_3402.jpeg

    Obviously, I still need to screen the sides & top. The bottom edges will attach securely to the shelf somehow. The back edges will attach magnetically to the camper side. I'm not thinking of double-sided tape, instead I'll epoxy steel washers directly to the camper.

    The trick remaining is attaching the frame to itself. I would love it if I could figure out a way to put a threaded post in the narrow sides of the frame on the front & side pieces and then a small wing nut on the fat sides where they poke through. That would seem plenty secure.

    More to come.
     
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    heySkippy

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  • #7
    I looked at the rivet nut stuff. I think it's overkill, at least for v1 of this project. It's a neat tool, though. When we get another house, I'll be wanting one.

    So, I bought a big roll of sticky backed Velcro and cut it down the middle to make 1/4" strips. I used these to attach the panels to each other and that seems to work well. I drilled several holes in the side that will touch the camper and put in washers and screws with a little dab of glue. Then I added weatherstrip to seal it to the camper.

    Finally, I glued little button moly magnets to the side of the camper. After assembling the cage on the ground it was nothing to step up the ladder and stick it to the wall of the camper.

    IMG_3410.jpeg

    IMG_3411.jpeg

    So, I still need to build and mount the shelf. I saved that for last and I'm still not sure how I'm going to hang it. I've been looking for low profile hangers but haven't found much so far. I want something sturdy, but as inconspicuous as possible.

    When the shelf is in place the bottom of the cage will attach to it. After that, the magnets' only job will be to hold the cage against the wall of the camper and I'm convinced they'll do that well.
     
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    heySkippy

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  • #9
    headache said:
    Perhaps a z-clip type bracket for attachment to the trailer wall? The shelf itself could have a vertical return so it's an L shape to provide surface to mount one side of the bracket. (Perhaps hinged for flat pack purposes?) Alternately, you could use a regular shelf hanging bracket and mount the z clip to that.
    Click to expand...
    That looks very similar to some extra heavy picture hanging brackets I saw yesterday. I think this was it.

    A big part of my hesitation is not knowing how that wall is constructed. I know it has an aluminum frame, but I can't tell for sure where they are under the fiberglass. I'm pretty sure there will be a vertical structure on either side of that window. I think there's a thin piece of plywood on the other side of the fiberglass. Using a long strip of a hanger like that would let me spread out the load on more, but smaller, screws.

    I should probably be asking about this bit over on an RV forum.
     
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    Drizzt321

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  • #10
    Z-clip, aka "french cleat" so to speak. Not exact, but very similar idea.

    Alternatively, you've got that nice big solidly anchored awning support there. Some clamps and a long angle brace, or even a long cut piece with 45-deg coming up to hold the center/far end, and the shelf going all the way to the support to be clamped on for that side/corner.
     
    Arcturus

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  • #13
    Yeah, I wasn't thinking anything too ridiculous, maybe even just a single post - the cage attached to the shelf provides the lateral stability by way of magnets, and a single post carries most of the load to the ground. Maybe a 2-part PVC pipe type deal, not even glued together since it would be a compression load (well, glue the coupler to one end so you don't lose it). Might need something clever to account for any uneven ground, but most camper pads are pretty flat.
     
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    heySkippy

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  • #14
    Wow...

    I've spent hours trying to think of every possible way to make this happen with an emphasis on not making more permanent mods to the camper than necessary and I never considered a "leg" to the ground for the shelf. Even if it won't work, it reminds me that I certainly have not thought of everything.

    IMG_6959.jpeg

    It would be a long leg, almost 9 feet to the ground. The small door on the right hides a propane tank and is rarely accessed but the big door on the left is our basement storage so I can't interfere with access to that. It's also a high traffic area, so there would need to be a way to guard against it being kicked or bumped out of place.

    This has given me fresh energy. I'll be out there today looking with a new eye. Thanks!
     
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    heySkippy

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  • #18
    Drizzt321 said:
    Don't want to leave the propane door open, both weather and possible critters getting into it.
    Click to expand...
    Interestingly, the propane bays (there's one on the other side also) are open in the bottom. A 30 pound tank sits on a metal frame with a strap to hold it. Hoses attach at the top and the bottom is open to the world. I assume this is to assure good ventilation in case of a leak.

    You had suggested earlier using the awning frame. I think that's what I'm going to do on the right side. I'll make a wire cable that attaches tot he right side of the shelf and runs up to the top of the frame.

    I'm still debating with myself about the left side. I have shifted to a "no holes" mindset. I want to make this happen without breaching the exterior of the camper.

    The shelf is wider on the left side. I'm looking at that speaker, considering hijacking an existing screw to support the left side of the shelf.
     
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    heySkippy

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  • #20
    After playing around with the awning frame and speaker screws this morning, I said enough and let myself drill baby drill. Just 4 holes, and they're small and they're way up high, but it needed to be done. I'm confident it'll be watertight and hold the shelf.

    So this is where I'm at. I drilled and mounted a couple hangers up high and used chain to brace the shelf which is Velcro'd to the wall of the camper. I've got a turnbuckle on each side to help with the leveling.
    IMG_3434.jpeg

    One surprise when hanging the cage was that with the shelf in place I can't put the cage on or off without retracting the awning.
    IMG_3438.jpeg

    Once it's all up there it's quite solid. I don't have any worries about it coming apart or the cats escaping. I do wonder how the Velcro will weather.

    Tomorrow I will figure out a way to prop the window all the way open and tuck the prop rod away. This will give the cats a lot more open area under the window. I don't want them to be able to accidentally close the window while they're outside.
    IMG_3445.jpeg

    I'm not entirely happy with the whole thing. Version 2 will have a number of changes, but this will do for now. One surprise has been the cost. I had expected this would be a cheap-ish project, but it hasn't been. Everything's gone up, I guess, and I did have to buy a couple things I probably would have had on hand back in our house. Still, that doesn't look like $100 to me.
     
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    Drizzt321

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  • #21
    Nice!

    And yeah, cost of things have really gone up.

    A bit late, but I imagine you could have gotten away with only the 2 upper holes. Used some nylon webbing or rope or similar to go straight down to the back side of the shelf against the trailer, as well as the diagonal to the front of the shelf. But I'm sure it's a lot more secure/stable this way.
     
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    heySkippy

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  • #24
    Well, the Catio survived its first disassembly/move/reassembly so I've got that going for me. There are a couple things I might do differently if I did it again.

    IMG_3512.jpeg

    For such a lightweight assembly, the Velcro works very well. Too well, in fact. I have to be very careful when disassembling that I don't bend the aluminum when pulling pieces apart. Also, sometimes the Velcro wants to stick to itself better than it is sticking to whatever I stuck it to. It was trivial to fix this time, but after repeated moves, it might not wear very well. It is also awkward to assemble when 3 sides of a piece are held by Velcro. On the plus side, once it is set up, it feels very rigid and secure.

    When I designed it, my aim was to make it fit in the basement as the very last thing to be loaded. That way the large front panel wouldn't have to get poked by anything. This seems to have worked well enough.
    IMG_3505.jpeg

    The cats have been using it, mostly at night. Anything that gets them off the bed when I'm sleeping is welcome! They are bed hogs.
    IMG_3519.jpeg
     
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