Gordinho80's Offroad / Camping Trailer Build

[Gordinho80]

Hi all. I'm new here so I figured I'd copy my Build Thread over from ExPo.

July, 2012...

I had been wanting to start a trailer build for some time. I've been looking for a good starting frame since. I wanted something on the cheap, and preferably with current registration. I stumbled across this one last week and immediately contacted the seller. I had contacted many sellers since I started looking, and only manged to get a hold of a couple. This guy contacted me and I had a feeling it would go through!

$100 asking price with registration. Went to look at it today. Seller arranged to have Notarized Bill of Sale and current registration. Seller admitted that there was a decent amount of surface rust, more so then he initially thought when he looked at it again yesterday. Agreed to discuss price when I went today.

Upon arriving and seeing the amount of surface rust, examined it and didn't find anything more then just that, lots of surface rust. He asked if I would do $50, I said $40. Agreed and we hooked it up. Lights all work minus 1 that is missing bulb and lens. Registration is current, expires in 3/2013. Torsion axles with oil filled hubs w/ indicator caps. LED tailights.

Drove it home without issue! Pulls like a dream. Seller gave me original title, bill of sale, and current registration (in his name). Now I start cleaning it and getting it ready for Phase 1; Utility type camper with walls.

[Gordinho80]

July, 2012...

Cleaned rust and painted...







MORE PROGRESS!

[Gordinho80]

July, 2012...

Picked up a new to me axle from Craigslist... same lug pattern as the wheels I'm mounting on the trailer...

Axle acquired!









Hubs look to be in really good shape for being 25-30 years old. The dust caps are screw on. The lugs are a little short, but they nuts thread fully with the H3 wheels mounted. They came off rather easily with the impact gun. 3 of the 4 U bolts came off easily, 1 had to be cut off. I plan on replacing them and the spring hangers as well. All in all... WELL worth $40!

[Gordinho80]

August, 2012...

Neighbor came through yet again with more steel! This time, 3" angle that he had 1 side cut down to 2.75" to fit inside the side rails of the frame! This is done to reinforce the sides where the springs mount. Got the angle cut down and tacked in place yesterday. Got the springs mounted today! My 1/2" drill bit took a **** on me, so I couldn't drill the axle enough to get the center pins inside the axle rod. So the axle is not 100% in place. Still need the wheel studs/nuts, but picking up some used 285/75-16 tires tomorrow to put on for the rest of this year. It should be rolling soon! Then I can build the box and extend the tongue.

[Gordinho80]

August, 2012...

Mounted tires onto the trailer wheels. Same size wheels/tires as my tow rig. Decided to take some pics of the progress... also decided to incorporate the newly acquired VW into things... Look how tiny it is!!!

[Gordinho80]

August, 2012...

12' long piece of 2.5" tube welded on and began welding the box frame.





A-frame welded on, welded corner uprights onto frame, and welded center brace. If you look on the rear uprights, you'll see a piece of thinner wall angle, this is going to be the top of the frame.

I've not decided yet what to make the walls out of, thinking some 1x6 or so pressure treated boards. I think maybe lining the metal with the same material that I used on truck's bumpers (visible in the first pic of this thread), in black, and a grey version on the boards. Thoughts?

[Gordinho80]

September, 2012...

Finished tacking up the frame. Difuser on the torch stripped and won't hold the tips, have to get a replacement from HF. Drilled out the frame and plywood and took it for a test ride down the street. It pulls perfectly!





When I got back, I started working on the fenders.

[Gordinho80]

September, 2012...

Finally figured out a design for the fenders. 1 is all tacked up. I ran out of wire so I couldn't fully weld it.

[Gordinho80]

October, 2012...

First trip with Phase 1 of the Offroad/Camping Trailer build...

Half of our gear for the weekend loaded up... picking up another couple and the rest of the gear...



All loaded and ready for the 275 mile drive to Watkins Glen, NY!





I NEED to get a camp kitchen set up on the side. Something to house stove and all the cooking gear, keep it away from our hang out/eating space, but still readily accessible. I also need to desperately start looking into on board water with water heater. No one was happy washing dishes with small jugs of cold water... lol

Oh, and a top! The neighbor already informed me that he brought home a sheet of 16 gauge....

All in all, though, the trailer was AWESOME! It towed beautifully. Fully loaded, there was no bouncing around and plenty of clearance to the fenders. I'm VERY happy with how it came out for Phase 1... Phase 2 will be some time until that gets started... but in the works!

[Gordinho80]

April, 2013...

Trailer has been sitting all winter but its time to start working on Phase 2!

I picked up an aluminum box that I am going to mount on the tongue to house my battery and other goodies. Also picked up a small fiberglass cap that I am going to make the top of the trailer.







Should have the 4x6" angle this weekend.

So I've been looking at this more and more... and I think I have it, finally!









Side boxes running the length of the trailer. They would start at the top frame and run all the way down to the top portion of the fender. I'm thinking 4x6 angle might be a little too much for a box frame, though. What about heavy duty plywood boxes? Would be a little easier to cut out and put together. Alternatively, I can get some smaller angle to make the frame out of? Only reason I'm doubting the 4x6 as a frame is because it would be about 13' on each side of 3/8" thick 4x6 angle! Thats a lot of weight.

So I've been talking to neighbor (who has been my steel supplier for this whole project)... Looking at the following...

Option 1:
4x6" angle ran along the top of the trailer frame front to back. I would run the 6" length horizontally to get a deeper box, more suitable for shovel, ax, hilift... Then, take the sheet steel I have which is like 3/16" I think, and cut 2 8" strips lengthwise. Notch and bend to make like a 6" C Channel, then bend and weld that to form a 16"x63"x16" U shape. This would be the sides and bottom of the box. I would use the rear flanges to bolt and weld it to the trailer frame. Then I would just need to make doors. The remaining piece of sheet steel would be enough to make 2 16" tall doors that I would get some smaller tube to frame.

Option 2:
He's checking to see if he can get me some thinner walled C channel, 6" wide, which I would make the entire box frame out of. It would be strong enough to support the cap, lighter than using the 4x6 all around, and less work than notching and bending flanges in sheet steel. I would still make the doors out of sheet steel and smaller tube.

I'm leaning toward option 2, to be honest. Hopefully I can get some thinner C to use.

[Gordinho80]

April, 2013...

Started working on the side boxes.







I'm picking up these doors from Craigslist...





$50 for all 3 doors! Just have to figure out sealing and the latch... Once I have them in my possession, it should be pretty easy to figure out. Hoping to have them by this weekend.

With the boxes, I ran silicon along each joint before screwing the pieces together. I'm going to cover the boxes with the same material as I used on the wood on the trailer. The tails will be housed on the back panels of the boxes, keeping them out of the way and easily accessible in case of failure.

Once the boxes are completed, going to mount the cap, after I paint it, of course. The question is... what color do I paint the cap? Same color as the boxes(grey) or as the steel on the trailer(black)? Then I need to focus on water setup and tailgate.

[Rainier70]

Interesting build, and nice work. I do most of my camping off road, so I am always looking for how others are building. I like how you roughed out with cardboard first.

Your trailer should be able to go most anywhere.