Don't have a name, pop-up toy hauler

[Dmanrick]

Well I wanted a small toy hauler to carry a couple of 4 wheelers in that can also be used as a camper. I thought about a cargo trailer but didn't want to do anything over 12 foot. The only way to get them both in a 12 foot trailer is to pull one in sideways and the cargo trailers weren't friendly for that.

So I decided to build my own popup toy hauler. It is like a cross between a cargo and a popup. I got a lot of inspiration from all of the posts here, especially the build by Fromeo.

I started by buying an old rotten Starcraft for parts. I tore it apart as soon as I got it.







Then I started building a new trailer.





Once I got the base frame done, I started working on integrating the popup components. I first mounted the assembly for the winch and wiffle tree.





I then started laying out the floor framework. I doubled up the square tubing where the tires would go as to keep from having any problems with the floor sagging when it is loaded.




It ended up looking like this once I got the flooring framework done. The jacks are welded on, bearings are all packed and the brakes are all adjusted.

[Dmanrick]

I didn't take any pictures of the wall framework or roof build but I am going to try to do better from now on.

Here is most of the wall framework done and the lift parts all working. I had to put the 4 wheeler on there to get an idea of how deep to make the roof. Here is the roof coming together and in different heights.





Once I got the roof built, I covered it in roll roofing and had to make corners out of abs for the trim. I was going to fiberglass the whole thing but after doing all of the corners, I had a change of plan.














Here the roof is back on the trailer and cranking up and down pretty good.

[Steve Frederick]

Welcome!
Glad to see that you got the build journal up!
This is very interesting. How does the roof lifting system work?

[Dmanrick]

Thanks for the welcome. I'll get some pics up tomorrow with all of that. I basically used the winch and lift system from the popup but like I said, I'll get some detailed pics tomorrow.

[pete42]

I like your build I always wondered if one could build their own HILO from an old popup looks like you might be on your way unless you are going to use canvas sides instead of wood

[vtx1029]

Nice! I like the ABS corner idea. So what does the trailer measure now?

[Dmanrick]

The box is 12'x7.5'

I haven't quite figured out what to do with the sides above the walls yet, That's why I posted it here, to maybe get some ideas. Hard sides wouldn't bother me but the only way I can think of is side walls that flip up and if I do that, I won't be able to do cabinets, etc. I'm kind of leaning towards using material for soft sides. Unless someone might know a way to make a hard side that folds in the middle, that might work. I just need them to attach to the bottom part and not the lid.

I am not going to utilize the pull out bunks from the old popup, with the doors on the side and end it wouldn't be very easy along with the fact that the handlebars would be in the way. It is also going to pretty minimal on the inside but I would like a couple of cabinets anyway.

[Dmanrick]

OK Here's some pics of the lifting system. It is off of the popup and please excuse the rust. I still have to paint a lot on the frame.

This is the winch that is mounted on the tongue.



This is the other end that hooks the winch onto the 4 cables going to each corner. As you can see, the middle 2 go to the back and the outer 2 go to each front corner around a pulley.



Front corner. All of the pulley assembly's came off of the popup except for 2 that I had to make.



Back of the trailer in the middle where the cables split to either side.



Back corner.



I got my flat bar that I am using for roof trim painted and will have it all up tonight. Here's the first piece up. Once I get them all on, I will trim the bottom of the plastic corners to match and the outside of the roof will be done until I mount the AC.





I also started building the gates for the opening to load and unload. I don't want to carry ramps so I am building them like a trailer. Here it is started, I still have to add some more to it.

[vtx1029]

How about hard sides that go on the outside like a hi-lo trailer?


http://www.hilotrailercompany.com/hilotrailercompany.com/Welcome.html

[wlivesey]

I think that hard sides might be a bit too heavy for the popup lifting mechanism. Well, if you build like I do.

Looking good!

[Dmanrick]

OK We got some work done this week. Mainly getting the sides all welded up and painted.























Going to get the floors in tomorrow and then start on the walls. I have the skins so it shouldn't be too bad.

[bc toys]

you are doing a great job this is one build i'm watching all the way

[Miriam C.]

Wonderful idea! Looking forward to seeing the finish!

[grizz]

Just got my internet back after 3 weeks... what a pleasure.

Nice to see your build journal.

Multi purpose is a good thing, look forward to the finish.

Oh, and welcome.

[Dmanrick]

Thanks.

Here's this weekends progress.

I got the floor in on saturday. I think it took as long to build the wheel wells than lay the actual flooring.






Sunday I got most of the framework completed for the aluminum siding. I am going to go back out in a bit and try to finish all of the framework. The only thing I really have left is the gates.





I did get one small piece of siding up to see how it would look. My wife is out of town and I'm going to need help on the bigger pieces so they will have to wait.