5x8 CT Bike Hauler and Camper

[davidshourd]

after lurking around here for a couple months and having the itch to get another project on my hands I finally pulled the trigger on a 5x8 CT. looked around at a couple places here in Spokane WA and found an outfit that could order up one in the color with a couple of the options I wanted from the factory. 3 LONG weeks later the trailer showed up. first picture is not it, almost it, just doesn't have the windows. upon ordering it I searched around for everything I would need to get this thing going for a mini toy hauler with the ability to convert into a quick set up camper/base camp area. ordering up the following to show up prior to the trailer (love amazon).
-(2) ARB awnings, one 8' for the curb side and one 4' for the back
-(2) 50W flexible solar panels
-(1) Optima bluetop battery that turned into two after the first one showed up with a crack that turned out to be repairable
-(1) tongue box
-(1) switches, fuses, wire
-(8) switchable LED lights
-misc stuff and things.

here is a couple pictures, apparently I can only upload 3 at a time. after a weekends of hard work I had the solar panels on, trailer wired, insulated, awnings on, and E track mounted.

0011.jpg (29.01 KiB) Viewed 34253 times

IMG_20140307_171741_014.jpg (103.42 KiB) Viewed 34253 times

IMG_20140226_183657_203.jpg (102.32 KiB) Viewed 34253 times

[davidshourd]

couple more pictures. I was not very good at taking pictures prior to the build. it was raining hard and wanted to get the thing in the garage. turned out I had to pull the tires and put it down on a couple moving dollies to get it in, was probably better as it made it possible to shift around during the garage build.

wiring schematic, pretty much followed it to a T.

wiring schematic.jpg (211.33 KiB) Viewed 34252 times

panels all caulked and insulation in. ran a couple flexible conduits to pull wire as well.

IMG_20140307_221159_174.jpg (89.46 KiB) Viewed 34252 times

tongue box with the flexible, yet liquid tight pathway for the main power. batteries live in there.

IMG_20140309_165002_998.jpg (103.57 KiB) Viewed 34252 times

[davidshourd]

back awning on, pretty straight forward attachment to the flat back wall.

IMG_20140307_221147_011.jpg (97.9 KiB) Viewed 34253 times

plywood back up. lights in, control panel under construction. (4) LED lights interior controlled at the main panel in the front with individual switching on each one as well.

IMG_20140309_180643_525.jpg (86.63 KiB) Viewed 34253 times

could not help but pull it out to deploy the side awning. this took some engineering to make work. I had some scrap aluminum pieces that had a 1" short leg with a 5" long leg, 1/4" material. I used that to create a near vertical service to mount the awning to. notice the lights on that side as well, they match on the other side of the camper.

IMG_20140310_180541_507.jpg (114.5 KiB) Viewed 34253 times

[davidshourd]

after about a week of cure time for the sealants I pulled it out to see how things were looking. bikes fit and solar panels were charging! next up is some sort of paint on flooring, I checked out a product at home depot the other day that looks pretty tough, forget the name right now but will post it up upon completion. then of course figuring out the fold down bed set up.

while the trailer was out I snapped a good picture of the solar set up on the roof. these are just adhered down. even on the cloudy day they were reading a charge!

IMG_20140310_180557_573.jpg (82.77 KiB) Viewed 34250 times

and might as well make sure the bikes are going to fit. one KLR650 (on the left) next to the KLR250 on the right. great fit.

IMG_20140311_175706_121.jpg (109.93 KiB) Viewed 34250 times

[lrrowe]

David,
I like it. Welcome aboard.

Can you share how you mounted the awnings to the CT and what is your experience with rolling them back? Easy, hard?

Bob

[davidshourd]

David,
I like it. Welcome aboard.

Can you share how you mounted the awnings to the CT and what is your experience with rolling them back? Easy, hard?

Bob

the back awning is just bolted onto the flat plate along the back of the trailer. these ARB awnings have an extrusion along the back that fits a 1/4" bolt head. allows the bolt to slide left to right but keeps them all in line up and down. then a little foam tape and some sealant to make sure everything stays water right.

The side awning was much more of a challenge with the radius of the roof. the way these awnings fold out they pretty much need to be plumb in the vertical or the extension arms that fold out to catch the end of the awning do not fold out level to the ground. so on the side I added a piece of 1/4" aluminum angle that had a 1" horizontal leg and a 5" vertical leg. this hit the radius of the roof/wall to a NEAR plumb condition. that was through bolted to the roof cross members and then thoroughly sealed up on the top and both sides. from there the awning was simple drilled, tapped and bolted to the 1/4" aluminum from within the enclosure of the awning. VERY stout and very weatherproof.

these awnings are not bad to roll back up. I had a 6' on a previous camper and that is about the biggest a single person can do. so the 4' is no problem. the 8' on the side requires two people until I maybe come up with a single person system for wrapping them up. once in a roll it fits up in its pouch and has three Velcro straps that keep it in place while you zip it shut.

ARB makes awesome products and these awnings are no exception. hold up great there wind, rain and sun. and with their ability to be quickly deployed it provides you with a little shelter as soon as you pull into camp.

[davidshourd]

here is the 6' awning deployed on the last set up I had. loved this set up!

P1280282.JPG (173.67 KiB) Viewed 34235 times

[jwhite]

I would like to know more about these awnings how much they cost and where to get one, I wish that someone would do a photo tutorial on installing one.
I found a local dealer that installs awnings but he wanted 600 to 1000 dollars and I also thought if I could do it myself and save money I would install one on both sides of the trailer.
I have a ezzup but for one person to put up and take it down it's a real pain to deal with.

[davidshourd]

ARB awnings can be found on Amazon for very competitive prices. sometimes you found a random website that will have a sale on them, but again, amazon usually carries the best msrp price on them.

the install of these is very simple assuming you have access to the back side (inside the trailer). even then if you do not you can mount them 100% from the outside you just have to be a little more diligent on sealing up the thing.

google ARB awning pictures. I found this picture that shows the extrusion on the back of these things that accepts the bolt heads. pre drill holes in the trailer, slide in, fasten up with appropriate washers and seal accordingly.

ARB track.jpg (38.95 KiB) Viewed 34209 times

[Rainier70]

Good looking CT. Mirage makes a well built trailer. Any trouble getting the plywood panels off, or did you request screws?

I like the look of your solar panels. Do you mind if I ask where you got them? Thanks.
cindy

[davidshourd]

Good looking CT. Mirage makes a well built trailer. Any trouble getting the plywood panels off, or did you request screws?

I like the look of your solar panels. Do you mind if I ask where you got them? Thanks.
cindy

They did use those silly nails, but not too much of an issue after reading about it here i knew what i was in for and tackled it correctly.

The solar panels are ebay panels from a company out of AZ, discount solar. I think. If you search for flexible panels there is a few people making and selling them. Including home depot online. I searched around to find the best price per watt and pulled the trigger after searching for a couple days.

[bc toys]

Welcome to this great site you have a nice trailer and are on your way to a great conversion can't wait to see your bed set up with those bikes in the trailer. Good luck and keep pics coming I love the solar and awning you have nice work on installing them

[davidshourd]

yeah, the bed set up should be interesting, thinking it will be a bi fold. one half folding down from each side to meet in about the middle. likely covering the windows when folded up, a little protection from bike handle bars!

I put on the first coat of the flooring last night. product is a restoleum product intended for concrete or wood decks. they had some samples of it at home depot and the stuff is solid. and it can be tinted to just about any color you could want.
http://www.rustoleum.com/product-catalo ... te-restore

I sanded the plywood with some 80 grit to get it a little more bite then vacuum cleaned it. from there this stuff has the consistency of frozen yogurt. very thick. I cut all the edges and up the wall in with a brush. hit all joints and screw holes with the brush too. then dumped it on and hit it with the texture roller it comes with. its a little colder then it likes to cure out in in my garage so it might take a week or so before it cures out. second coat will go on tonight hopefully.

IMG_20140318_185617_997.jpg (84.04 KiB) Viewed 34080 times

[aggie79]

I really like what you're doing with your CT conversion. Thank you for the tutorial on the ARB awnings. Please report back on how you like the Re-Store product.

[lrrowe]

David,
I like it. Welcome aboard.

Can you share how you mounted the awnings to the CT and what is your experience with rolling them back? Easy, hard?

Bob

the back awning is just bolted onto the flat plate along the back of the trailer. these ARB awnings have an extrusion along the back that fits a 1/4" bolt head. allows the bolt to slide left to right but keeps them all in line up and down. then a little foam tape and some sealant to make sure everything stays water right.

The side awning was much more of a challenge with the radius of the roof. the way these awnings fold out they pretty much need to be plumb in the vertical or the extension arms that fold out to catch the end of the awning do not fold out level to the ground. so on the side I added a piece of 1/4" aluminum angle that had a 1" horizontal leg and a 5" vertical leg. this hit the radius of the roof/wall to a NEAR plumb condition. that was through bolted to the roof cross members and then thoroughly sealed up on the top and both sides. from there the awning was simple drilled, tapped and bolted to the 1/4" aluminum from within the enclosure of the awning. VERY stout and very weatherproof.

these awnings are not bad to roll back up. I had a 6' on a previous camper and that is about the biggest a single person can do. so the 4' is no problem. the 8' on the side requires two people until I maybe come up with a single person system for wrapping them up. once in a roll it fits up in its pouch and has three Velcro straps that keep it in place while you zip it shut.

ARB makes awesome products and these awnings are no exception. hold up great there wind, rain and sun. and with their ability to be quickly deployed it provides you with a little shelter as soon as you pull into camp.

Thanks,
I understand what you did and also found several "how to's" on Youtube. I think this awning is a strong candidate for my "must have list". If I go with it, I think I will think about some system where I drive with it inside the CT and then quickly slide the back plate into place when I get to a camp spot. This would help keep the sides smoother for traveling.

I liked the way one Youtube installer made a swinging rig so the awning could travel and be set up on the side and then if desired, swung to the back if he wanted to use it over his Bard Doors.
This link is a video for a similar mount (towards the end of the video). But there is another one that was a DIY rig, but I cannot find it now.

http://www.youtube.com/watch?v=PXaqWF8xnfA

Edit
And I found the DIY swing arm.
http://www.clubhummeroffroad.com/forums ... g-swingarm