working on it wrote:working on it wrote:working on it wrote:working on it wrote:(from 10/23/13)... even now, I'm starting more makeovers : removed the toolbox and battery to make a spacer/platform for a much larger, aluminum tonguebox (haven't ordered it yet). But, I'm making the platform based on the dimensions shown on its ebay listing. I used some treated lumber that I used on the original trailer. I put it on it 18 years ago (removed it before starting this build, and it sat in the woodpile for two years), and its still good. The older treated lumber is better than the new stuff.
I spent more time last week on the tonguebox platform; made a baseplate for the aluminum box (ordered it), bought some slide mounts to install between the box and the tongue spacer, and painted all the wood. Today (11/2/13), I installed the slidemounts,
and awaited the delivery of the aluminum box, from FedEx. I checked out every vehicle coming down the street (dead-end, so if I missed the delivery coming in, I'd catch it coming out). No delivery....
Update, one week later(11/9/13)...... got the tonguebox... Today, I fitted the plywood baseplate (w/3 coats of aluminum heavy duty paint), drilled holes (waterproofed the drilled spots), and bolted it to the slide mounts (with ten 3/8" bolts, fender washers, and nylocks). Test fit the new box, and tested functionality prior to bolting it to the baseplate (tomorrow). Here's pics:
Will also mount the pull handle, locking device, support casters under the baseplate, and install the battery and charger inside the box (if I have the time). I've been working 12-13 hour days, with no breaks (or much help) for two weeks straight (Sat-Sun off), and commuting 120 miles round-trip each day. At 63, I've sorta started showing signs of slowing down (at least on weekend projects).
Next day (11/10/13): did a parts inventory, figured I still needed the casters and some shrink tubing, as well as a few more 3/8-16 bolts for the box hold-downs. The wife wanted to get a coupla items at the Home Depot as well, so we went there together. While there, getting the parts, I also threw in another item (a backup digital test meter-Greenlee), and was ready to get back to the tonguebox. I caught her looking at "sale" tools, for Xmas items, and casually mentioned the fact that a year ago I was promised a Milwaukee combo of cordless tools (to finish the trailer build). Then I went back, to fetch another extension cord for the tonguebox, and returned to see her buying the impact driver and drill set for me!. This set:
After we got home (after a long sidetrip to Wallyworld) and ate lunch, I mounted the casters
like this (bad photo)
Then, with light running out, I mounted the baseplate pull handle(s), one on top and one below, and hurriedly took pictures.
I had charged both of the new tools' batteries while having lunch, so I got to use both today. Wonderful! I sure missed using my friend's Snap-On tools since I brought my trailer build home from his shop; now (a little late for the hard parts of the build), I have the "good" tools I had needed for so long.
Final chapter "slide mounted aluminum tonguebox " episode: Yesterday (11/16/13), I mounted the box on the baseplate (with four 1/4-20 stainless bolts, and 3/16" steel angle stock along front and rear box walls, and two 3/8-16 bolts w/fender washers on both sides of the box/baseplate-about midway along each sidewall edge), and when fully tightened down, it would not slide. Obviously, there was binding along the slide axis, so I removed it, re-aligned the holes, re-drilled, and re-set the baseplate. While doing so, I eliminated 3 bolts per side of the slide-mount to baseplate interface (redundant hardware) and used grade five 3/8"-16 bolts and nylocks to secure. I also lubed the slide-bars! When I had the baseplate off, I also moved the support casters forward to be centered during the entire range of travel.
I then added a lockable hasp at the underside handle, to secure the assembly at the fully rearward travel position (and prevent unauthorized access to the spare tire, which is still chained and locked, as well).
I mounted the battery footing plate to the center (for weight balance) of the box/baseplate with four #10 woodscrews (will also mount a securing strap over the battery top, later). With the battery mounted, I drilled two holes in the backside of the box (on the right) to run the 4ga/12vdc cables thru. I used 3/4" outside diameter hose to protect the cables, and tie-wraps to lock in place.
As completed so far:
But as this next picture shows
, the box came without weather seal under the lid. I'll add that today, and also make a secure mount for the charger inside the box, hook up the battery (and cover the exposed terminals), and toss in all the remaining extension cords, testers, adapters, and other electrical gear I installed this box to house. All this gear transferred to the front box will bring the Tongue Weight to around 160lbs, or 11.2% of total. And, here's my new calculated "centers of gravity" (horizontal and vertical):
- centers of gravity.jpg (114.33 KiB) Viewed 850 times
Worth all the time and effort.
P.S. the finishing touch>>>the name of the trailer put on the box 
by Martiangod » Mon Nov 11, 2013 8:20 pm 
Roly, still thinking out of the box.........damn it.
Then I topped off the batteries with water (even though they are about shot). Next I've got a couple of bolts to fix that pulled through the floor. 
