20' Enclosed trailer converting to luxury toy hauler

[Brian556]

Just posted this in the introductions section but thought it would probably make more sense putting it here instead
Howdy,
Wanted to introduce myself and say how much I appreciate this site. I've been dreaming of building a custom toy hauler for my ATVs for years now. I've looked and looked at the different types of commercial built toy haulers and could not find anything that fit my needs or my budget. I finally pulled the trigger on an enclosed trailer last month and have started the process. This site has been an awesome source of information. Ive only scratched the surface as to all the info on here but will be spending a lot of time learning from you guys. I have about 8 days left to prep for a 3 week camping road trip to Wyoming with my kids. I did a similar trip last year but we slept in the back of my truck and had an open utility trailer. I posted a write up of it on expedition portal http://www.expeditionportal.com/forum/threads/84323-Tampa-to-Colorado-with-a-truck-homemade-camper-ATVs-and-two-kids
Below is a picture of the new to me 20'X8'X6'6"2010 V nose trailer.




I want to keep track of everything and post lots of pics to hopefully get some feedback and ideas from you guys
This is what Ive done so far
Installed some E track to attach removable bunks


Welded up some folding bunks




took down the paneling and added foam board insulation
My son helping me

We labeled all the panels and trim pieces with tape and made a fancy cheat sheet for each wall so we could figure out how to put it all back together




I got all the insulation done yesterday. Today Im cutting out holes for my window unit, vents, and my 14"X22" vertical sliding windows that just came in the mail yesterday!!! I am really nervous about cutting holes in the trailer. We'll see how it goes. If you guys have any tips on how to do this I sure would appreciate it. the skin is thin sheet metal, studs are 1" thick square tube, and interior ply is 3/8th.

Thanks!!
Brian

[dustboy]

Hi Brian, Good to see another ExPo guy on here. Looks like you're off to a solid start!

[hankaye]

Brian556, Howdy;

Welcome to the forum!

As far as doing your windows check out the topic at the top of the list here in Cargo Trailers.
It's had some good reviews.
What you've already done and shown us in the pix. looks like you know your way around a
work shop. You shouldn't have any problems. Please keep us up to date.

hank

[Quadriderdad]

Welcome from Oregon!...looks like you're off to a great start!

[roadinspector]

Brian556,

Welcome! Looks like you got a good start. Keep at it. This place helped me a lot. As far as window install, I agree, the first post is where you need to go for that. Read as many post as possible, many many good ideas.

Earnest

[OverTheTopCargoTrailer]

Hi Brian556

Very Nice truck that you have , but where does the "luxury" in the toy hauler part come from ?

Will you be using lots of this stuff in blue to match your TV ??

Marina blue anodized satin finish Diamond plate




http://diamondlifegear.com/diamond-plate-aluminum.htm?chs=9#stp2

[Brian556]

Hi Brian556

Very Nice truck that you have , but where does the "luxury" in the toy hauler part come from ?

Will you be using lots of this stuff in blue to match your TV ??

Marina blue anodized satin finish Diamond plate




http://diamondlifegear.com/diamond-plate-aluminum.htm?chs=9#stp2

When you see the 5 gallon bucket crapper and folding lawn chair dinette set you will understand why I call it "luxury"

[OverTheTopCargoTrailer]

Ok .....

Now I see you are using more like German Humor
Sorta like Nice trailer - but crappie tow vehicle


I always got in trouble and yelled at when I used that growing up
Don't worry I have a 5 gallon crapper too , because why do you need to haul around an
Extra 100 gallons of liquid crap , why do RV people have a need to float their sh** ?
It's a downright waste of water - required by the Gov !!!
Requires an expensive toilet - needs repairs , requires extra dump trips , still smells like crap ,
Most likely overloads your tires....., Yada Yada Yada !!


Keep posting the pic's


Jerry

[Brian556]

Well Ive been hard at it the last couple days and even though Im running out of time before our 3 week trip to Wyoming I feel like I got a lot of things done. The first huge hole I reluctantly cut was the opening to mount the 8,000 BTU A/C unit I bought from lowes. After trying a 12,000 BTU portable unit I decided this was the route I wanted to go. They are cheap to replace, way cheaper than a roof mount unit and I don't have to worry about the weight on my flat roof sagging and causing leaks.
Here's some pics:

Taped the opening



Made the cut. I used a metal blade in a jig saw for the thin stuff and then a sawsall to get through the stud. After that I had to use an angle grinder to cut the stud down 1" on the top and bottom to fit in my frame pieces.












All welded up. The bunks I made were actually the first thing Ive ever welded besides practicing on scraps. I know they aren't pretty but seem to be getting good penetration with minimal burn throughs









Homemade metal brake for bending the aluminum flashing for inside the frame






Test fitting and drilling side flanges I made out of 1" angle iron



The hole



It is hot as balls in here!!!




Installed and sealed. This thing rocks! I was working on interior stuff yesterday and had it on full blast. I was actually a bit chilly in there which is a huge relief. I was worried it would not be big enough.

[OverTheTopCargoTrailer]

Did you happen to know what the outside max air temp was ?
Were you parked in the full sun or shade ?

Also what was your inside low temp after running unit a few hours ??
I'm trying to compare different usage & graph insulation values & power usage


Thanks Jerry

[Brian556]

The outside air temp was around 90 something with about 75% humidity
R 3 3/4" foam board between the studs
Not sure what the ceiling has as it was already done when I bought the trailer. Probably similar stuff though
It sits in the florida sun all day long
It takes about an hour in the heat of the day if I try and cool it off after it gets really hot. Ounce the humidity is reduced inside it really feels a lot better. It will still be a bit warmer in the back of the trailer until it runs for probably 2-3 hours

[drcurran]

How many BTUs for the AC unit you installed. Nice install by the way!

[hankaye]

Brian556, Howdy;

Question about why you installed it on the front, aren't you concerned
about damage to the cooling fins on the condenser? Perhaps you've designed
a cover for it you haven't fabricated and have ready to show us yet.

hank

[OverTheTopCargoTrailer]

Hi brian

thats pretty good for only 8,000 Btu in full sun at 90 deg ....
Did not think a small unit would work that well

don't worry about the front install, worst case after 50,000 miles you get a few stuck bugs.
I would however recommend not driving uncovered in the poring rain

when I get my insulation done, I'll let you know how mine turns out....
as bodies and appliances also produce some heat - not in my calculation.

im hoping 7 x 18 will do 100 deg full sun, with 5,000 btu on only solar
so far so good on shore power test & with empty trailer, but not sure if it works as well
because the inverter & charge controller make some heat also ?

jerry

[Brian556]

Brian556, Howdy;

Question about why you installed it on the front, aren't you concerned
about damage to the cooling fins on the condenser? Perhaps you've designed
a cover for it you haven't fabricated and have ready to show us yet.

hank

I know, I stressed about that for a while but decided I wanted mount it permanently so I could lock it down solid and seal it up real good. I am concerned about the issues of having it on the front but am determined to figure out a way to make it work. Funny enough I noticed one of the crappy gray plastic storage bins I had in my garage actually fit over it pretty well....Gonna have to see what we can do with that.
I figured worse case if I don't have anything worked out by Monday it will be trash bag and ratchet strap style