New Foamie Hybrid build * Frame Finally Done! *

[DJT]

What suspension will you be using for offroad?

Also if you can get a axle with the same wheels as you main off road tow car you would then have 2 spares and thats handy off road

Well I have a set of 500# trailer leaf springs, but they are quite short, so I picked up a set of leafs from the rear of a Ford Ranger...We'll see how they look under the frame, and I also expect a set of Monroe shocks will make it into the mix.

If that doesn't look like it's going to do what I need it to, a friend has a set of Firestone air bags from another project sitting in his garage...

I had actually intended to use my Jeep tires/wheels on the trailer (since they are 50% or so) and buy 4 new ones for the Jeep, but i have the others already, and it's some $$$ that can go towards foam for now.

Started sticking metal together today after HOURS of grinding industrial powdercoat off the steel... Sometimes free doesn't seem like such a great deal...

[Conedodger]

Sometimes free doesn't seem like such a great deal...

Free is always a good deal.

I remember when i was in business a guy came in and asked what my best price was on a part (I sold car parts to Garages)

I gave him the price and he gave me a long hard luck story (That was obviously made up) to get it cheaper, this went on so in the end i said

"Dont worry mate, You can have it for Free!"

What did he say

"Can i have two?"

Cheeky git

[DJT]

Progress pics from 05/27/11!

Laying out the frame:


Looks like everything is going to fit! But it seems a whole lot smaller in real life!

90% tacked up:


Got it square on the first try! Now just have to keep it true while finish welding...

You can see the industrial powdercoating in these pictures...The steel is from overseas shipping frameworks for industrial heavy machines, and the coating is designed to withstand multiple open air ocean crossings so is VERY heavy and has to be ground off before any welding or fitting...But it was free!

[GPW]

DJ, Very Cool you can do that ... Thrifty too ... Building it's half the Fun anyway ...

[Conedodger]

We find that when welding powder coated steel, cut it to size and place it all together then run the ginder just down the corner where you are welding.

did that when i modified my bumper the other week



this leaves the maximum powdercoat intact

[DJT]

Good idea Cone (and nice bumper!).

Picked up a trial piece of 2" foam today (and a free counter top!) to work out door and hatch sealing... :confused: any ideas?

[DJT]

Look what just arrived:



and:

[eaglesdare]

i just want to cry! i am so turning green from envy of that pic!

would it be too noisey to ask how much you paid? how many sheets is there? is it all 2 "

you are one lucky foamer!

[DJT]

Eagle, that is 19 pieces of 2x8x2" ship lap board (the odd piece on top is an oddball?). I found it on Kijiji (like CL), got it for about $13/pc. Very happy since they are $27/pc. from the local big box stores.

I'm hoping to only use about 13 pieces for this build, so I'll have some left over for "next"!

Now just need glue and two more sticks of tubing. My son and I are going shopping on Friday while mom is away, then I'll have 6 days to build!!!

[eaglesdare]

great buy! can't wait to see what you come up with in those 6 days.

[Wobbly Wheels]

DJT, if you don't mind my asking, what did it cost to ship the foam ?
I assume they cubed it because of the weight ?

I ask because I don't really want to buy the quantity I need through the local building supply because they are pricey anyway and won't give me a break on the quantity I need. I can go to Vancouver and pick it up for about $6 a sheet less so I'd have to buy a lot to make it worth the cost of the trip.
If I can get it shipped over though...

Also, since it sounds like you're a car guy kicking around suspension ideas...
When I was younger, I worked for a Chrysler for about 5 years while I was going to school. I recall people buying up Caravan axles for trailers - they've already got the axles and brakes and the leaf springs have bolt on hangers. IIRC, the hubs are a common bolt circle so rims are easy to find as well. I've been planning on using one for mine, but lately I've been thinking more about using a trailing arm axle from a FWD car and using struts rather than springs.

Any thoughts on the idea ?

[GPW]

Anybody want to split a pallet of Foam with me ... ??? One would guess that buying in quantity would be Cheaper ... hopefully !!

None of the box stores here carry the 2" ... grrrrr!!!!

[eaglesdare]

i only wished i could!. do you have any idea how much a pallet would be? and how many sheets?

[GPW]

Eagle , I called Loew's Help line ... They have to route the order through a store , The representative said she'd contact the local store Manager and he would give me a call with the specifics ... Will relay to you as soon as I know anything ...

[DJT]

WW, I looked at a couple of options for suspensions, including Caravan rear axles, VW torsion bars, and even a Civic double wishbone with struts. All have some advantages (not least of which is price!), but the absolute simplicity and trail repairability of leafs and a solid axle won out. I have built a couple of trailers with re-purposed axles, and they worked well, but I often had to fab parts to get them to work, and if they break on a trip... Struts are also bulky and hard to build into the trailer body.

I picked up the foam, I was out for a charity trail run, and it was just a little out of the way!

When I asked about a pallet of foam I was told that the 2x8x2" came in 6/pk bundles, 8/pk to a pallet. At $25-$27/sheet...