8x16 Cargo Trailer Conversion: Design Choices, Build Steps, and Lessons Learned

[outintheforest]

I pick up my new Cargo Mate trailer on Tuesday.

7' interior height, 32" RV door (I'm surprised this is so uncommon) & 50" tongue.

I chose 8' width because everything 7' and wider uses the same width axle and 8' 6" seemed wider than I want to deal with.

I chose barn doors because I don't think the utility of a ramp door is worth the space penalty. A ramp door means that I can't open the door when it's inside my 30' shop, so no loading it or working on it inside. Any vehicle going into it will be well under 300 pounds, and a portable ramp isn't a big deal.

I've been spending the last month deep in Autodesk Fusion, planning my layout and 3D printing some miniatures. I like to see the results on screen, as well as in real 3D space.

I went with tandem 3,500 pound axles on traditional springs. My camp sites are usually at the end of very long dirt "roads", and I'm of the opinion that a spring axle is more robust, and easier to repair than torsion.

Layout:

• Minimalist bathroom in front, with a separating toilet & shower.
• The front also houses the electrical system - shore power, inverter, solar charge controller and battery storage
• Kitchen, storage and couch in the mid section
• platform bed that can be raised to the ceiling in the back, with room for a motorcycle, bicycles, etc, under the bed. It'll normally be 24-30" off the floor.

I have the electrical system laid out, and the plumbing will be extremely simple. I'll bring it home, make measurements and see how large of a window I can put in the kitchen.

Can't wait to get started.

 

[outintheforest]

Well, I wasn't expecting the trailer to be ready until the end of February and it was a nice surprise to get the call so early in the month. I have a friend who lives near the factory, and rather than have it delivered I did the factory pickup option.

If you do this, be aware that not all companies will give you title and DMV paperwork. I had no proof of ownership or a temporary plate to drive home with. I had about 2 1/2 hours of freeway and 30 miles of narrow, 2 lane, rural roads to get home. It tows great, which isn't surprising because it's behind a 1 ton diesel 4x4.

Once home, I did a bunch of measuring so I could update the CAD drawing to reflect the real values.

Then I started the dismantling process. I should have asked the factory to not install the 1/8" plywood trim, as they used 1,000 small staples. That'll take some time to clean up.

I needed to know exactly where the studs are, so I can place the windows. I found some very nice windows, but at $600 to $800 each it was out of the budget (and kind of silly). Then I found the Chinese manufacturer of those exact windows, and they sell direct at about $150 each. Shipping to my door on 4 windows is about $250, and includes all costs. I'd rather buy US made, but I haven't seen a US made window that I like. The only downside of buying direct is the 30 day shipping time, although for $575 I can have 7 day delivery, but I don't think there's a need.

I also need a method to support the studs where they will be cut out for window installing. I think I have it figured out. China is on vacation for 2 weeks, so I have time to design and test the mechanism.

The next steps:

• Repair the factory wiring to remove the Scotch Locks in the electrical system.
• Order water tanks (clean and gray) to fit between the floor beams.
• Order some lights, to check placement and finalize the electrical system
• Decide on the exact window size and placement
• Insulate under the floor
• Paint the bottom of the subfloor with bedliner
• Cardboard mockup of some of the interior pieces

 

[outintheforest]

All the plywood is out, and I measured the floor beams for the possibility of putting a gray water tank under the subfloor, but not below the level of the beams - I don't want to damage it off road.

I realized I'd ding the walls while working on the interior, so I got the insulation (1" XPS) cut to size and installed. Lots of it will need to come down again, but it'll be worth it protect the skin.

Lights arrived, so I can have an idea of how many I need. I'll do a temporary install and see just how bright they are at night.

I have a better idea of the window placement.

Fortunately I remembered to remove all the Forest River & Cargo Mate stickers before they bake in the sun and become permanent.

Electrical parts and solar hear is starting to arrive. Lot of blue Victron boxes...

 

[featherliteCT1]

Lot of blue Victron boxes

Oh yeah!!