Denali toyhauler build thread (in progress) 060813

[gregert12]

Hey TNTTT,



Here is my trailer build thread which is based on Gadgetman's (I have no where NEAR his ability to make cabinets or a friend to work pro bono.) All this work was completed in a weekend since next week we will be camping at the Carlisle, PA swap meet. As a bonus, pretty much everything I had sitting around the yard. The requirement is to be able to 1- pull in a Jeep TJ (lifted/locked) or 2-get 4 Yamaha grizzly atvs to fit.

<edit 042713> Well, it looks like I skewed from gadgetman's floor plan/living quarters/cabinet ability just a "little bit."



Anyway...



Base model Car Mate 8.5' x 22'
Twin 6000lb torflex axles
+ 6" height
+"get out door" on the opposite side
+4' v-nose for mpg/storage


Painted off-white/eggshell from the bare wood...

Railed both sides... 2 layers



Needed some storage... also ran 45ft of string LED light, for low amp. ext power needed...


Strap holder...


Ran a hard line out of 12/3 for the Honda generator, ran through the channel and custom tie down...


Tongue was 18" longer as per the sales rep since we had to worry about the tailgate vs the jack, now shortened to 6 inches, what a waste of 300.


A leftover DiamondBack low profile cab guard from a Colorado works great for storage and as a the light control box...


A little red neck with the signal stick...


Needed more storage and the micro is mounted up...


Manual vent mounted 4ft from the back...


Powered vent 4 ft from the front...



Linoleum the floor, 2qty, 8x12 sheets, perfect width, used carpet tape to hold it down.


Picked up a 18"x24"x7' cabinet from Home Depot, "scratch and dent" for $150 w/ tax vs $220+. Had to rebuild the back since the staples came out, fix the broken slider drawer (bent wheel) ** to be minwaxed ** Really wanted a 24" depth.


Secured it to the top with the 2x4 brackets (through bolted 2 per bracket, 4 brackets in all) and had it sit out from the "V" for the mini toilet.


Humm... How can I hide this and create privacy? I got it! Instead of bending rebar and welding brackets, I took a prebent piece of aluminum, 3 wire loom clips, an old bathtub privacy screen and bolted it in. Can't beat free.


Curtain open..


Need a laptop tray for when we are in the back sleeping or outside it. Took a piece of scrap, cut it 17"x17", use 2 brass hinges and bolt it up.

Open------------


Closed with a bungee----------


Current setup---






To be finished...

minwax/seal cabinet
find a 12" wide cabinet, for by the door
find a counter top to span the door to the V nose

[bc toys]

nice work on your trailer, thanks for pics , enjoy it

[Accordnc]

Looks good keep up the good work

[pete42]

Nice!

pete

[8ball_99]

Nothing wrong with that. Looks like your off to a good start.

[revorunner]

Good job!

[eaglesdare]

good job, but i really had to say i love the curtain!

[pete42]

good job, but i really had to say i love the curtain!

I wonder why you like it?................I really know why just kidding.

pete

[gregert12]

Hurricane Sandy put a hold on this project since we are fixing up the shore house but my plans are to remove the front vnose section, get a 36", 16" and another 12" cabinet to fill in along the vnose to straight box section, cover the top with fiberglass 4 ply, get a horizontal cabinet on the top, close the one side and make a tray for the porta pot/shower pan made out of a water heater drip pan.

I have been looking at the fold out beds on ebay and bolt on the sides, the misc water fittings +40 gallon tank and an on demand hot water heater

[gregert12]

Time for a complete overhaul for the upcoming riding season... (28hrs build time)


new tank (30 gallon) and freebie cabinet.

Tank Info:
One piece seamless construction
Includes 4 fittings:
One) 1 1/4" Dia x 2" T Boss fitting for the water intake
Three) 1/2" Dia screw in fittings
Measurements for Tank (not including fitting): 34 1/2" X 12" X 17 1/2" (tank can sit on all sides except fittings)

Water Pump Info:
Made by Flojet model #03526144





tank and storage bins we picked up at the swap meet


tank test fit location


btm insulation


that will work for space savings


fittings (drain 3/8" barb, fill, vent, 5/8 out to pump)


wrapped with 5/8" poly board closed cell foam, R3 value. strapped down with stainless steel strapping


5/8 line to the pump


(hole in the wall is shore feed)


potential fill spout and vent location (inside fill/vent for tank and ext fill bypasses the tank/pump)


shore feed




mocked up wall for storage on the left


first shelf 2x 1/2 plywood to protect the tank


perfect fit in the cabinet, woohoo! the wrapped cord will be for the water heater


freebie counter top (temp) with fill/vent lines




potential setup




cabinet moved up, to the right of it is the back door screen


with the current portapot location, there is plenty of room

[gregert12]

PD4045 AC to DC converter

[Gadget Man]

Gregert12

Your build Looks great so far. feel free to copy anything from my build. That's the whole idea of posting pictures.
Building cabinets are really not that tough, you just build boxes and put a front faceplate on.

How do you like that Mr Heater ?
My next trailer may be smaller, and I'll just go with one of those for heat.

Gadget Man

[gregert12]

Gregert12

Your build Looks great so far. feel free to copy anything from my build. That's the whole idea of posting pictures.
Building cabinets are really not that tough, you just build boxes and put a front faceplate on.

How do you like that Mr Heater ?
My next trailer may be smaller, and I'll just go with one of those for heat.

Gadget Man

Thanks,

With the trailer not being insulated, the Mr Heater provides more than enough heat. The exterior vent is left open for positive air flow and the Co2 detector is on the floor.

[Gadget Man]

Gregert12

I'm going to re-plumb my entire water system this spring.
I need to raise my pump up higher like you did so its easier to drain and winterize before winter freeze.
My current set-up is with simple barb fittings and vinyl hose. It works just fine, but hard to disconnect and drain.
I'm going to switch to threaded connections.

How many bikes are you trying to fit into your trailer?

Gadget Man

[gregert12]

We can fit four, full size, Grizzly 700s from the tailgate to the cabinet with seven inches to spare. This setup should keep 10-15% of the weight on the tongue. In order to get the bikes in, we would take them through the passenger door and use an atv jack to slide them to the back.


Crap, I did not think about winterizing the system. Well the lowest point is the tank since everything will either drain to the outside shore fitting from after the pump and the tank has a side drain which is the farthest towards the rear. If I jack up the trailer tongue the full 25 inches or so, there would probably be a couple cups of water that will not naturally drain out. I'll cross that bridge in the fall.


-Greg