And We're Off! - First Time Build

[2one8]

Welp, I've kicked off the build. I've been lurking and learning for a while, time to make something happen.

I do a lot of cross-country travelling to go hiking and back-country backpacking, and in the past I've always stayed at hotels or even crashed in the car at trail heads or camp grounds, and while that worked fine for me, it doesn't work well for the girlfriend and limits us on where we can bring the pup. I've had the idea of a small pull-behind camper, but they get so damn expensive to buy pre-built. This will allow us to crash pretty much anywhere if needed, utilize camp grounds for frequent and hopefully eliminate hotels all-together.

The idea was a small, lightweight design that's large enough for the girlfriend and I and the pup, easy to set up/break down, and off-road capable for any overlanding in the future. Decided on 5x8 trailer for the base, "semi-square drop" teardrop design with 3ft inside height and a basic rear galley. Structure will be 2x3 studded frame with ply exterior and NRP interior, insulated with foam panel, and skinned with aluminum sheet. We don't need much and are fine with minimalistic. Hoping to have this finished by mid-June for a maiden trial trip to Michigan. I anticipate ~$2000 before adding accessories.

Most of the builds and forums I've been reading everyone designs their own CAD files before building and have it down to a science, I'm just winging it and everything is in my head. So here goes nothin!

Started on the frame. I searched and searched for a 5x8 trailer to build off, but all I could find was drop gate utility trailers that would have been $1,000+ before modifications for a used one, so I decided to build one instead. 2x2 .120 wall steel tubing with Flexiride 2,000# Torsion Half Axles. 2x2 .120 is probably overkill, but I wanted to make sure it was sturdy and robust enough for anything off-road. I went with the Flexiride for the smoother ride, ground clearance, and adjustable ride height. I haven't completely decided on wheels/tires yet, but leaning towards Falken Wildpeak 215/75R15 on black steel wheels. With todays prices I have $536 in steel from a local shop. Another $491 for axles after shipping. I need to pick up one more cross-member piece tonight because I didn't take into consideration the axles would need their own. I fully expected to have to fight with the frame since I'm not a professional builder or welder and I'm not using a jig, but to my surprise the frame has stayed square and true after welding, I even tacked into place the tongue last night (no photos yet) and thats within 1/16th from side to side. Hopefully thats a sign of things going well moving forward.

Also don't judge me on my welds. I've seen much worse on here!

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[2one8]

Apparently we can only attach 3 photos at a time...

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[tony.latham]

You know, it sounded perfect until I read this:

3ft inside height...

We find it important to be able to sit up inside ours. Just like the teardrop cabins that have been built for the last 80 years. A 4' tall cabin.



We eat inside during inclement weather. On our recent three-week teardropping trip, we played cards inside almost nightly because it chilled off so fast.



But anywho, good luck with your build!

Tony

[2one8]

You know, it sounded perfect until I read this:

3ft inside height...

We find it important to be able to sit up inside ours. Just like the teardrop cabins that have been built for the last 80 years. A 4' tall cabin.

Yeah I guess I should have said roughly 3ft as that is what I need to sit upright. I'll likely give a little more in the end but try to keep it no more than 40" because I want to maintain one 4x8 sheet for the sides while trying to cover the frame, but if need be I can use diamond plate to cover the frame. We aren't going to use a big thick mattress and instead look at either those3-4in foam or using our 2-person backpacking mattress, so once the floor is done I was going to measure again and see what I need. I used my backpacking tents as a reference and we have room to sit upright in those. I don't want to get too tall and end up towering over the vehicle roof, especially since eventually there will be a rack and basket on top.

[tony.latham]

That'll work fine.

a big thick mattress..

Our mattress is every bit as good as what's in our bedroom. It's 5" of medium density with a 3" foam topper bonded to it. Dreamy, is the word that comes to mind.



:thumbs-up:

Tony

[2one8]

After speaking with a good friend I may be taking this in a little different direction. He is a very competent and experienced metal fabricator and informed me he has everything we would need to build this using steel C channel frame and alum skin. Finished weight will be around the same but far more sturdy, and cost me far less than what I have figured using wood. Our new end goal is a trailer very similar to the XTR Off-road from Vintage Trailer Works. I will update as we go!

[2one8]

UPDATE:

Finished the trailer frame. We will make some small tweaks to it as we go for things I didn't take into consideration, but overall it turned out pretty good. Far better than I expected.

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[2one8]

Picked up the flooring, insulation, and interior walls and drug everything 3 hours to my buddies shop. The trailer pulled very well, no noise, no vibration, tracked straight. We planned out the dimensions (we made a far better drawing than my professional wing it drawing on the plywood) and started creating the CAD drawings to cut the supports. We will use a 14 gauge C-channel design for any corners/ends that the insulation will slide into, and a Z-channel for all supports in between. The outer skinning and interior panels will be riveted to the c-channel, and we will make our own 1-piece trim to finish it off. Toolbox will sit on the tongue as shown and the spare tire will sit between the box and the cabin.

I was extremely fortunate to meet Mike years ago while riding motorcycle. We were the only two guys in the area with the same bike and just happened to meet in a parking lot. Ever since then we have been close friends. He is a specialized fabricator and welder and managed a motorcycle racing team for many years and I helped with bike setup and prep on race weekends, and now any project I can think up he tells me to bring it over.

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[2one8]

I downloaded Sketchup, here is the end goal.

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[tony.latham]

I downloaded Sketchup...

I've worked up teardrop plans using graph paper and Sketchup. The latter really helps work out details that would be difficult --or impossible-- with paper.





Your design looks damn snazzy.

Tony

[2one8]

Weekend update:

We got quite a bit done on Saturday. Received the doors, ceiling fan, fenders, hurricane hinge, cowboy shower, and water pump. We got most of the cabin framing done. Material is 16ga steel, laser cut and formed into C-channel so the foam panels can slide in the channel. We still need to add a couple ceiling crossmembers, frame in the fan, and frame in the cowboy shower.

I have a long weekend coming with Memorial Day, so hopefully we can have this finished or just needing the small things next weekend. I won't have the wheels and tires yet, so I will just continue to use the ones on it now that I borrowed from my car trailer.

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[2one8]

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[2one8]

Update:

It was a long Memorial Day weekend but we got some good progress done.

Frame was painted (minus tongue, still some welding to do there), flooring bottom layer was coated in roofing tar and let to dry overnight. Once dry it was placed into the trailer, insulation and floor framing was done, and top layer installed.

We made the fresh water tank a little larger since we had the material. It now holds 25 gal, which is likely far more than we need. Pump is mounted underneath and will get a vented cover to keep grime and what-not from building op on it. Since this is towed with my X5 we aren't too worried about damaging the tank, but if it does become a concern later on we can make a belly pan for it.

Installed the roof fan framing and started planning out the rear hatch area. I didn't get any photos of the hatch progress yet.

Interior walls are rough cut and test fit. We had to add some bracing to the ceiling to mitigate sag. I also cut the wall insulation panels and test fit them.

Next steps, all the tedious trimming, accessory location planning, wiring, etc.

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[2one8]

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[2one8]

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